STATOR CORE COMPRISING COBALT CARBIDE AND METHOD OF MAKING THE SAME

• US 20200136440A1
• Filed: 10/31/2018
• Published: 04/30/2020
• Est. Priority Date: 10/31/2018
• Status: Abandoned Application

• Current Assignee: Hamilton Sundstrand Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Original Assignee: Hamilton Sundstrand Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Inventors: Cohen, Zachary, Policandriotes, Tod
• Application Number:
  US16/176,706
• Publication Number:
  US 20200136440A1
• Time in Patent Office: Days
• CPC Class Codes: H01F 1/26 by macromolecular organic substances
• CPC Class Codes: H01F 41/0246 Manufacturing of magnetic circuits by moulding or by pressing powder magnetic cores made by moulding or by pressing powder H01F27/255; soft magnetic particles H01F1/20, H01F1/36
• CPC Class Codes: H02K 1/02 characterised by the magnetic material
• CPC Class Codes: H02K 1/16 Stator cores with slots for windings
• CPC Class Codes: H02K 1/20 with channels or ducts for flow of cooling medium
• CPC Class Codes: H02K 11/0141 Shields associated with casings, enclosures or brackets
• CPC Class Codes: H02K 15/02 of stator or rotor bodies
• CPC Class Codes: H02K 15/024 with slots
• CPC Class Codes: H02K 5/02 Casings or enclosures characterised by the material thereof

Abstract

Disclosed is an electric machine, comprising: a rotor; and a stator core radially outward from the rotor, the stator core being stationary relative to the rotor during operation; wherein the stator core comprises: carbon fibers and cobalt carbide, and wherein the stator core is greater than or equal to 40% cobalt by weight. A method of forming a stator core, comprising: coating a plurality of carbon fiber sheets with a mixture of resin and cobalt powder, wherein the resin is a phenolic resin, a powdered pitch resin, or a combination comprising at least one of the foregoing; pressing together the plurality of carbon fiber sheets; heat treating the plurality of carbon fiber sheets to form cobalt carbide in the carbon fiber sheets; and forming a plurality of laminations from the resulting mixture to produce the stator core.

Claims

1. An electric machine, comprising:

a rotor; and

a stator core radially outward from the rotor, the stator core being stationary relative to the rotor during operation;

wherein the stator core comprises;

carbon fibers and cobalt carbide, and

wherein the stator core is greater than or equal to 40% cobalt by weight.

2. The electric machine of claim 1, wherein the electric machine is an electric motor or an electric generator.

3. The electric machine of claim 1, wherein the stator core comprises a plurality of laminations.

4. The electric machine of claim 1, wherein the stator core comprises a plurality of mechanical teeth extending radially inward toward the rotor.

5. The electric machine of claim 1, wherein the stator core comprises a plurality of heat fins extending radially outward and away from the rotor.

6. The electric machine of claim 1, further comprising a housing radially outward from the stator core.

7. The electric machine of claim 6, wherein the housing provides electromagnetic shielding for the electric machine.

8. The electric machine of claim 6, wherein the housing comprises:

carbon fibers and cobalt carbide, and wherein the housing is greater than or equal to about 40% cobalt by weight.

9. The electric machine of claim 1, wherein the stator core comprises less than or equal to about 1% iron by weight.

10. The electric machine of claim 1, wherein the stator core comprises 0% iron by weight.

11. The electric machine of claim 1, wherein the carbon fibers comprise carbon fiber cloth, graphene, chopped carbon fibers, carbon microfibers, carbon nanofibers, or a combination comprising at least one of the foregoing.

12. The electric machine of claim 1, wherein the carbon fibers have a laminar orientation.

13. The electric machine of claim 1, wherein the carbon fibers have a random orientation.

14. The electric machine of claim 1, wherein the stator core comprises carbon fibers within a cobalt/cobalt carbide matrix.

15. The electric machine of claim 1, the stator core comprises about 40% to about 70% cobalt by weight.

16. The electric machine of claim 1, wherein the stator core comprises about 5% to about 30% carbon fibers by weight.

17. The electric machine of claim 1, wherein the stator core comprises about 0.01% to about 5% cobalt carbide by weight.

18. The electric machine of claim 1, wherein an average molecular diameter of the cobalt carbide is less than or equal to about 100 nanometers.

19. A method of forming a stator core such that the stator core comprises carbon fibers and cobalt carbide, and wherein the stator core is greater than or equal to about 40% cobalt by weight, the method comprising:

coating a plurality of carbon fiber sheets with a mixture of resin and cobalt powder, wherein the resin is a phenolic resin, a powdered pitch resin, or a combination comprising at least one of the foregoing;

pressing together the plurality of carbon fiber sheets;

heat treating the plurality of carbon fiber sheets to form cobalt carbide in the carbon fiber sheets; and

forming a plurality of laminations from the resulting material to produce the stator core.

20. A method of forming a stator core such that the stator core comprises carbon fibers and cobalt carbide, and wherein the stator core is greater than or equal to about 40% cobalt by weight, the method comprising:

mixing phenolic resin, cobalt powder, and carbon fibers;

die casting the resulting mixture; and

forming a plurality of laminations from the mixture to produce the stator core.