Reinforced rotor assembly and method of making same

Claim 2

A rotor assembly comprising: at least one stiffening ring including at least two radially outwardly extending tangs; at least two flux ring segments of magnetic flux conducting material, each of said flux ring segments disposed about the outer circumference of said stiffening ring with at least one tang separating each adjacent pair of said flux ring segments; a magnetic body mounted on each of said flux ring segments, each of said magnetic bodies including an arcuate outer surface, said magnetic body outer surfaces forming a substantially cylindrical rotor surface generally coaxial with said stiffening ring; mounting means for providing an axis of rotation for said rotor assembly; and a matrix disposed between said stiffening ring, said flux ring segments and said mounting means for maintaining the relative positions therebetween.

Claim 3

The rotor assembly of claim 1 wherein: two of said stiffening rings are disposed generally coaxially and with said tangs in opposing alignment; and said flux ring segments are disposed so as to bridge the outer circumferences of said stiffening rings with at least two opposing said tangs separating each adjacent pair of said flux ring segments.

Claim 4

The rotor assembly of claim 2 wherein: each of said stiffening rings comprises metal; said tangs are disposed at regular intervals about the circumference of said stiffening rings and terminate at said rotor surface; each of said flux ring segments comprises an arcuate piece of sheet material; and each of said magnetic bodies further includes an arcuate inner surface for mounting on said flux ring segments.

Claim 5

The rotor assembly of claim 2 wherein said mounting means includes a shaft extending through said stiffening rings and disposed generally coaxially therewith.

Claim 6

The rotor assembly of claim 2 wherein each of said flux ring segments includes at least one bendable tab positioned to engage said matrix.

Claim 7

The rotor assembly of claim 2 wherein each of said flux ring segments includes at least one bendable tab positioned to engage its respective said magnetic body.

Claim 8

The rotor assembly of claim 2 wherein said matrix comprises a plastic.

Claim 9

The rotor assembly of claim 2 wherein: each of said tangs comprises a generally U-shaped channel having its walls disposed in contact with the adjoining flux ring segments; and said matrix is further disposed between each of said magnetic bodies.

Claim 10

The rotor assembly of claim 2 wherein: said outer surface of each of said magnetic bodies includes at least one chamfered edge; and said matrix is further disposed over each of said chamfered edges for bonding said magnetic bodies to said rotor assembly.

Claim 11

The rotor assembly of claim 2 wherein said magnetic bodies are adhesively bonded to said flux ring segments.

Claim 12

A rotor assembly comprising: at least two metal stiffening rings, each of said stiffening rings including at least two radially outwardly extending tangs spaced at regular intervals about the circumference of said stiffening ring, said stiffening rings disposed generally coaxially and with said tangs in opposing alignment; at least two flux ring segments of magnetic flux conducting material, each of said flux ring segments comprising an arcuate piece of sheet material, each of said flux ring segments disposed bridging the outer circumferences of said stiffening rings with at least two opposing said tangs separating each adjacent pair of said flux ring segments; a magnetic body mounted on each of said flux ring segments, each of said magnetic bodies including an arcuate inner surface adjoining a flux ring segment, each of said magnetic bodies further including an arcuate outer surface, said magnetic body outer surfaces forming a generally cylindrical rotor surface, each of said magnetic bodies further including at least one chamfered edge; each of said tangs terminating at said rotor surface; a shaft extending through said stiffening rings and disposed generally coaxially therewith; a plastic matrix disposed between said stiffening rings, said flux ring segments, said shaft, said magnetic bodies, and over the chamfered edge of each of said magnetic body outer surfaces; and each of said flux ring segments including at least one bendable tab positioned to engage said matrix and one bendable tab positioned to engage said magnetic body.

Claim 13

A rotor assembly comprising: at least two metal stiffening rings, each of said stiffening rings including at least two radially outwardly extending tangs spaced at regular intervals about the circumference of said stiffening ring, said stiffening rings disposed generally coaxially and with said tangs in opposing alignment; at least two flux ring segments of magnetic flux conducting material, each of said flux ring segments comprising an arcuate piece of sheet material, each of said flux ring segments disposed bridging the outer circumferences of said stiffening rings with at least two opposing said tangs separating each adjacent pair of said flux ring segments; a magnetic body mounted on each of said flux ring segments, each of said magnetic bodies including an arcuate inner surface adjoining a flux ring segment, each of said magnetic bodies further including an arcuate outer surface, said magnetic body outer surfaces forming a generally cylindrical rotor surface, each of said magnetic bodies further including at least one chamfered edge; each of said tangs terminating at said rotor surface; a shaft extending through said stiffening rings and disposed generally coaxially therewith; a plastic matrix disposed between said stiffening rings, said flux ring segments, said shaft, said magnetic bodies, and over the chamfered edge of each of said magnetic body outer surfaces; and each of said flux ring segments including at least one bendable tab positioned to engage said matrix and one bendable tab positioned to engage said magnetic body.