Thermally matched composite sleeve
First Claim
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1. A rotor for an electrical machine comprising:
- a rotor core substantially comprised of a first material;
a plurality of permanent magnets carried on the rotor core, the plurality of permanent magnets substantially comprised of a second material that is different from the first material; and
a sleeve about the rotor core and the plurality of permanent magnets the sleeve comprising a fiber-reinforced composite layer about the rotor core and the plurality of permanent magnets, the fiber-reinforced composite layer comprising;
a plurality of elongate fibers,a polymer binder that, together with the plurality of elongate fibers, provides a majority of the support retaining the plurality of permanent magnets to the rotor core, an aggregate effective coefficient of thermal expansion of the elongate fibers and the polymer binder being disparate from the aggregate effective coefficient of thermal expansion of the plurality of permanent magnets, andan additional doping material, at least a portion of the sleeve about the rotor core and the permanent magnets having a coefficient of thermal expansion that is substantially equal to the coefficient of thermal expansion of the plurality of permanent magnets.
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Abstract
A sleeve about an electric machine rotor core and the plurality of permanent magnets has a fiber-reinforced composite layer about the rotor core and the plurality of permanent magnets. At least a portion of the sleeve about the rotor core and the permanent magnets has a coefficient of thermal expansion that is substantially equal to the aggregate coefficient of thermal expansion of the rotor core and the plurality of permanent magnets.
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Citations
18 Claims
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1. A rotor for an electrical machine comprising:
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a rotor core substantially comprised of a first material; a plurality of permanent magnets carried on the rotor core, the plurality of permanent magnets substantially comprised of a second material that is different from the first material; and a sleeve about the rotor core and the plurality of permanent magnets the sleeve comprising a fiber-reinforced composite layer about the rotor core and the plurality of permanent magnets, the fiber-reinforced composite layer comprising; a plurality of elongate fibers, a polymer binder that, together with the plurality of elongate fibers, provides a majority of the support retaining the plurality of permanent magnets to the rotor core, an aggregate effective coefficient of thermal expansion of the elongate fibers and the polymer binder being disparate from the aggregate effective coefficient of thermal expansion of the plurality of permanent magnets, and an additional doping material, at least a portion of the sleeve about the rotor core and the permanent magnets having a coefficient of thermal expansion that is substantially equal to the coefficient of thermal expansion of the plurality of permanent magnets. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A rotor for an electrical machine comprising:
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a rotor core substantially comprised of a first material; a plurality of permanent magnets carried on the rotor core, the plurality of permanent magnets substantially comprised of a second material that is different from the first material; and a sleeve about the rotor core and the plurality of permanent magnets, the sleeve comprising a fiber-reinforced composite layer about the rotor core and the plurality of permanent magnets, the fiber-reinforced composite layer comprising; a plurality of elongate fibers, a polymer binder that, together with the plurality of elongate fibers, provides a majority of the support retaining the plurality of permanent magnets to the rotor core, an aggregate effective coefficient of thermal expansion of the elongate fibers and the polymer binder being disparate from the aggregate effective coefficient of thermal expansion of the plurality of permanent magnets, and an additional doping material, at least a portion of the sleeve about the rotor core and the permanent magnets having a coefficient of thermal expansion that is substantially equal to the aggregate coefficient of thermal expansion of the rotor core and the plurality of permanent magnets. - View Dependent Claims (11, 12, 13, 14)
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15. A method of retaining elements of an elongate electric machine rotor, the method comprising:
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retaining a plurality of permanent magnets to a core of the rotor with a sleeve comprising a fiber-reinforced composite layer, the fiber-reinforced composite layer comprising; a plurality of elongate fibers, a polymer binder that, together with the plurality of elongate fibers, provides a majority of the support retaining the plurality of permanent magnets to the rotor core, an aggregate effective coefficient of thermal expansion of the elongate fibers and the polymer binder being disparate from an aggregate effective coefficient of thermal expansion of the plurality of permanent magnets, and an additional doping material, the fiber-reinforced composite layer having a coefficient of thermal expansion that is substantially equal to the coefficient of thermal expansion of the permanent magnets; and expanding the fiber-reinforced composite layer substantially along the length of the core of the rotor in response to a change in temperature in approximately the same amount as the permanent magnets expand along the length of the core of the rotor in response to the change temperature. - View Dependent Claims (16, 17, 18)
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Specification