Method of fabricating rotor assemblies having chemically bonded lamination stacks

• US 7,788,792 B2
• Filed: 12/12/2006
• Issued: 09/07/2010
• Est. Priority Date: 10/16/1997
• Status: Expired due to Fees

• Current Assignee: Honeywell International Inc.
• Original Assignee: Honeywell International Inc.
• Inventors: Menon, Mambailykalathil N., Meacham, Walter L.
• Primary Examiner(s): Tugbang; A. Dexter
• Assistant Examiner(s): CAZAN, LIVIUS RADU
• Application Number:
  US11/609,578
• Publication Number:
  US 20070079497A1
• Time in Patent Office: 1,365 Days
• Field of Search: 295/96, 295/98, 310/45, 310/216, 310/217, 310/261, 310/216.065, 156/89.16, 427/104, 427/123
• US Class Current: 29/598
• CPC Class Codes: F16C 32/0468 of moving parts of the magnetic circuit, e.g. of the rotor
• CPC Class Codes: H02K 1/02 characterised by the magnetic material
• CPC Class Codes: H02K 1/04 characterised by the material used for insulating the magnetic circuit or parts thereof
• CPC Class Codes: H02K 1/06 characterised by the shape, form or construction
• CPC Class Codes: H02K 1/24 Rotor cores with salient poles ; Variable reluctance rotors
• CPC Class Codes: H02K 15/02 of stator or rotor bodies
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49012 Rotor

Abstract

A rotor assembly or other rotating device having a stack of laminations or laminates that are chemically bonded together. Chemical bond of the laminates may have a strength that approaches the strength of the material of metal laminates. Chemical bonds may be effective in holding the laminates at temperatures when subject to rigorous mechanical operations such as high rotation speed and vibration.

Claims

1. A method of fabricating a rotor assembly, comprising:

polishing a plurality of laminations of magnetic material;

removing carbon and impurities while annealing each of the polished laminations in a carbon removing atmosphere;

applying a metallic plating to the annealed laminations;

oxidizing the plated laminations by heating each of the plated laminations while exposed to air;

applying a dielectric chemical bonding agent to the surfaces of the oxidized laminations;

stacking the laminations;

applying the chemical bonding agent to spacers;

stacking the spacers at the end of the stacked laminations; and

applying a thermal cycle to the stacked laminations and spacers to cure the chemical bonding agent such that the laminations maintain a bond in operating temperatures over 1000°

F.

2. The method of claim 1 where the carbon removing atmosphere is moist hydrogen.