Permanent magnet generator

Claim 2

An electromagnetic device for use as a generator or alternator comprising a plurality of magnetic laminations arranged to form a stack, each of said laminations being of at least substantially square configuration and formed as a single piece to reduce the magnetic reluctance of the lamination, each of said laminations having a pair of opposed legs with the legs of the laminations in said stack aligned to form a pair of opposed magnetic cores, a coil wound around each of said cores, the thickness of the coil around each core being at least approximately equal to the length of each core, and a permanent magnet rotor mounted for rotation between said cores, said rotor including a permanent magnet which is magnetized in a direction perpendicular to the rotational axis of said rotor, the spacing (A) between the tips of said cores being equal to the length (B) of the legs forming said cores which is in turn equal to the width (C) of said cores, and the width (D) of said frames being equal to at least approximately one-half the width (C) of said cores.

Claim 3

A device according to claim 1 wherein said coils are of rectangular cross section.

Claim 4

A device according to claim 1 wherein said permanent magnet has a coercive force (Hc) of at least approximately 6,000 eorsteds.

Claim 5

A device according to claim 3 wherein said permanent magnet is comprised of a rare earth - cobalt.

Claim 6

A device according to claim 3 wherein saId permanent magnet is comprised of R-cobalt, where R is selected from the group consisting of samarium, praseodymium, misch metal, cerium, lanthanium, neodymium, and combinations thereof.

Claim 7

A device according to claim 1 wherein said permanent magnet is formed as a right circular cylinder.

Claim 8

A device according to claim 1 wherein said permanent magnet is formed as a portion of a right circular cylinder with flat parallel surfaces on opposite sides of the rotational axis of said rotor.

Claim 9

An electromagnetic device for use as a generator or alternator comprising a plurality of magnetic laminations stacked together, each of said laminations comprising a unitary and at least substantially square frame forming a low reluctance magnetic backpath for the lamination, each of said laminations having a pair of opposed integral legs with the legs of the laminations aligned to form a pair of opposed magnetic cores, a coil of at least substantially square cross section around each of said cores, said coils extending from said frames to the tips of the legs forming each core, and a permanent magnet rotor mounted for rotation between said cores, said magnet having a coercive force (Hc) of at least about 6,000 oersteds and being formed as a portion of a right circular cylinder centered about the rotational axis of said rotor, said magnet having a pair of parallel flat sides defining a thickness dimension for said magnet only slightly less than the distance between the tips of said cores, said magnet being magnetized in a direction parallel to said flat sides and perpendicular to the rotational axis of said rotor.

Claim 10

An electromagnetic device for use as a generator or alternator comprising a plurality of magnetic laminations stacked together, each of said laminations comprising a unitary and at least substantially square frame forming a low reluctance magnetic backpath for the lamination, each of said laminations having a pair of opposed integral legs with the legs of the laminations aligned to form a pair of opposed magnetic cores, a coil of at least substantially square cross section around each of said cores, said coils extending from said frames to the tips of the legs forming each core, and a permanent magnet rotor mounted for rotation between said cores, said magnet having a coercive force (Hc) of at least about 6,000 oersteds and being formed as a portion of a right circular cylinder centered about the rotational axis of said rotor, said magnet having a pair of parallel flat sides defining a thickness dimension for said magnet only slightly less than the distance between the tips of said cores, said magnet being magnetized in a direction parallel to said flat sides and perpendicular to the rotational axis of said rotor.

Claim 11

A device according to claim 8 wherein said laminations are electrically insulated from each other.

Claim 12

A device according to claim 8 wherein the spacing (A) between the tips of said cores is equal to the length (B) of the legs forming said cores which is in turn equal to the width (C) of said cores.

Claim 13

A device according to claim 10 wherein the width (D) of said frames is equal to at least approximately one-half the width (C) of said cores.

Claim 14

A device according to claim 8 wherein the length of said permanent magnet along said rotational axis is at least approximately equal to the overall thickness of the stacked laminates.

Claim 15

A device according to claim 8 wherein said rotor comprises said permanent magnet, and a pair of stub shafts secured to opposite ends of said magnet.

Claim 16

A device according to claim 8 including a housing surrounding said laminations.

Claim 17

A device according to claim 14 wherein said housing comprises a cup and cover, each of said cup and cover supporting a bearing for said rotor.

Claim 18

A device according to claim 15 wherein said cup and cover are made of plastic and sealed together.

Claim 21

A method according to claim 17 including inserting said laminations, coils and rotor into a cup shaped housing, and closing off the open end of said housing.