US4939398A — Laminated assemblies with in situ molded magnets

Claim 1

Independent Claim 107 words

A rotor for a dynamoelectric machine comprising: a rotor body of ferromagnetic material or the like, said body being composed of a plurality of laminations and defining at least one magnet slot therein; a permanent magnet formed in situ in its respective slot without an air gap between the magnet and the slot, said magnet being formed from a cured mixture of magnetizable particles in a binder, said slot being configured to retain the magnet in place therein; the laminations being skewed with respect to each other, said permanent magnet slot being thereby skewed as well, said permanent magnet being formed in situ in said skewed configuration.

Claim 2

Dependent Claim 107 words

A rotor for a dynamoelectric machine comprising: a rotor body of ferromagnetic material or the like, said body being composed of a plurality of laminations and defining at least one magnet slot therein; a permanent magnet formed in situ in its respective slot without an air gap between the magnet and the slot, said magnet being formed from a cured mixture of magnetizable particles in a binder, said slot being configured to retain the magnet in place therein; the laminations being skewed with respect to each other, said permanent magnet slot being thereby skewed as well, said permanent magnet being formed in situ in said skewed configuration.

Claim 3

Dependent Claim 37 words

The rotor as set forth in claim 1 wherein the rotor body has a plurality of magnet slots therethrough, further including a plurality of permanent magnets, one for each slot, formed in situ in its respective slot.

Claim 4

Dependent Claim 48 words

The rotor as set forth in claim 1 wherein said permanent magnet has a density substantially greater than the density of the loose magnetizable particles from which it is composed, said particles in the process of making the permanent magnet in situ being subjected to a compressive force.

Claim 5

Dependent Claim 19 words

The rotor as set forth in claim 3 wherein the compressive force is approximately 66 tons per square inch.

Claim 6

Dependent Claim 21 words

The rotor as set forth in claim 1 wherein the magnet slot is configured to retain the permanent magnet in place.

Claim 7

Dependent Claim 20 words

The rotor as set forth in claim 5 wherein the magnet slot through each lamination is encircled by its lamination.

Claim 8

Dependent Claim 39 words

The rotor as set forth in claim 1 wherein the permanent magnet is formed in situ in its slot without significant shrinkage of the material of which the magnet is composed to preclude the formation of an air gap.

Claim 9

Dependent Claim 95 words

A precursor to a stator assembly for a dynamoelectric machine comprising: a stack of stator laminations of ferromagnetic material or the like, each lamination having a plurality of magnet slots formed therein, the laminations being aligned so as to form a plurality of continuous magnet slots extending through the stack; a plurality of unmagnetized permanent magnet precursors, one for each slot, formed in situ in their respective slots without an air gap between each magnet precursor and its slot, said unmagnetized magnet precursors being formed from a cured mixture of magnetizable particles in a binder.

Claim 10

Dependent Claim 95 words

A precursor to a stator assembly for a dynamoelectric machine comprising: a stack of stator laminations of ferromagnetic material or the like, each lamination having a plurality of magnet slots formed therein, the laminations being aligned so as to form a plurality of continuous magnet slots extending through the stack; a plurality of unmagnetized permanent magnet precursors, one for each slot, formed in situ in their respective slots without an air gap between each magnet precursor and its slot, said unmagnetized magnet precursors being formed from a cured mixture of magnetizable particles in a binder.

Claim 11

Dependent Claim 105 words

A permanent magnet assembly comprising: an assembly body of ferromagnetic material or the like, said body being composed of a plurality of laminations and defining at least one magnet slot therein; a permanent magnet formed in situ in its respective slot without an air gap between the magnet and the slot, said magnet being formed from a cured mixture of magnetizable particles in a binder, said slot being configured to retain the magnet in place therein; the laminations being skewed with respect to each other, said permanent magnet slot being thereby skewed as well, said permanent magnet being formed in situ in said skewed configuration.

Claim 12

Dependent Claim 105 words

A permanent magnet assembly comprising: an assembly body of ferromagnetic material or the like, said body being composed of a plurality of laminations and defining at least one magnet slot therein; a permanent magnet formed in situ in its respective slot without an air gap between the magnet and the slot, said magnet being formed from a cured mixture of magnetizable particles in a binder, said slot being configured to retain the magnet in place therein; the laminations being skewed with respect to each other, said permanent magnet slot being thereby skewed as well, said permanent magnet being formed in situ in said skewed configuration.

Claim 13

Dependent Claim 48 words

The precursor as set forth in claim 8 wherein each permanent magnet precursor has a density substantially greater than the density of the loose magnetizable particles from which it is composed, said particles in the process of making the permanent magnet precursors being subjected to a compressive force.

Claim 14

Dependent Claim 22 words

The precursor as set forth in claim 8 wherein each magnet slot is configured to retain its permanent magnet precursor in place.

Claim 15

Dependent Claim 21 words

The stator assembly as set forth in claim 11 wherein each magnet slot through each lamination is encircled by its lamination.

Claim 16

Dependent Claim 77 words

A precursor to a permanent magnet assembly comprising: an assembly body of ferromagnetic material or the like, said body defining at least one magnet slot therein; an unmagnetized permanent magnet precursor formed in situ in its respective slot without an air gap between the magnet precursor and the slot, said unmagnetized magnet precursor being formed from a cured mixture of magnetizable particles in a binder, said slot being configured to retain the magnet precursor in place therein.

Claim 17

Dependent Claim 77 words

A precursor to a permanent magnet assembly comprising: an assembly body of ferromagnetic material or the like, said body defining at least one magnet slot therein; an unmagnetized permanent magnet precursor formed in situ in its respective slot without an air gap between the magnet precursor and the slot, said unmagnetized magnet precursor being formed from a cured mixture of magnetizable particles in a binder, said slot being configured to retain the magnet precursor in place therein.

Claim 18

Dependent Claim 39 words

The permanent magnet assembly as set forth in claim 9 wherein the assembly body has a plurality of magnet slots therethrough, further including a plurality of permanent magnets, one for each slot, formed in situ in its respective slot.

Claim 19

Dependent Claim 48 words

The permanent magnet assembly as set forth in claim 9 wherein said permanent magnet has a density substantially greater than the density of the loose magnetizable particles of which it is composed, said particles in the process of making the permanent magnet being subjected to a compressive force.

Claim 20

Dependent Claim 21 words

The permanent magnet assembly as set forth in claim 15 wherein the compressive force is approximately 66 tons per square inch.

Claim 21

Dependent Claim 47 words

The stator assembly as set forth in claim 8 wherein the magnetizable particles of a particular slot are compressed together in the process of forming the magnet in situ, said compressed particles being thereafter cured in situ without significant shrinkage, thereby precluding formation of an air gap.

Claim 22

Dependent Claim 22 words

The permanent magnet assembly as set forth in claim 9 wherein the magnet slot through each lamination is encircled by its lamination.

Claim 23

Dependent Claim 41 words

The permanent magnet assembly as set forth in claim 9 wherein the permanent magnet is formed in situ in its slot without significant shrinkage of the material of which the magnet is composed to preclude the formation of an air gap.

Claim 24

Dependent Claim 47 words

The permanent magnet assembly as set forth in claim 9 wherein the magnetizable particles of the slot are compressed together in the process of forming the magnet in situ, said compressed particles being thereafter cured in situ without significant shrinkage, thereby precluding formation of an air gap.

Claim 25

Dependent Claim 126 words

A rotor assembly for a permanent magnet dynamoelectric machine comprising: a set of laminations secured to form a rotor body, each lamination including a plurality of generally V-shaped slots therein, said V-shaped slots of the various laminations being substantially identical, the laminations being rotationally skewed with respect to each other; a rotor shaft disposed along the longitudinal axis of the rotor body; and a generally rectangular permanent magnet disposed in each leg of the V-shaped slots; the V-shaped magnet slots being shaped so as to receive the rectangular permanent magnet through all the skewed laminations with a minimum air gap; each leg of the V-shaped slots being generally wider at each end of the leg and tapering to a waist near the midpoint of the leg.

Claim 26

Dependent Claim 126 words

A rotor assembly for a permanent magnet dynamoelectric machine comprising: a set of laminations secured to form a rotor body, each lamination including a plurality of generally V-shaped slots therein, said V-shaped slots of the various laminations being substantially identical, the laminations being rotationally skewed with respect to each other; a rotor shaft disposed along the longitudinal axis of the rotor body; and a generally rectangular permanent magnet disposed in each leg of the V-shaped slots; the V-shaped magnet slots being shaped so as to receive the rectangular permanent magnet through all the skewed laminations with a minimum air gap; each leg of the V-shaped slots being generally wider at each end of the leg and tapering to a waist near the midpoint of the leg.

Claim 27

Dependent Claim 77 words

The rotor assembly as set forth in claim 2 wherein the waist separates each side of its leg into first and second portions, the first portion of a first side of each leg of the V-shaped slot being generally parallel to the second portion of the opposite, second side of that leg and the first portion of the second side of each leg being generally parallel to the second portion of the first side of that leg.

Claim 28

Dependent Claim 21 words

The rotor assembly as set forth in claim 21 wherein the base of the V-shaped slot is generally elongated and rounded.

Claim 29

Dependent Claim 126 words

A rotor assembly for a permanent magnet dynamoelectric machine comprising: a set of laminations secured together to form a rotor body, each lamination having at least a first magnet slot therein, said first magnet slots of the various laminations being substantially identical, the laminations being rotationally skewed with respect to each other; a rotor shaft disposed along the longitudinal axis of the rotor body; and a generally rectangular permanent magnet disposed in the first magnet slot; the first magnet slot of each lamination being shaped so as to receive said rectangular permanent magnet through all the skewed laminations with a minimum air gap; the magnet slot being generally wider at each end of the slot and tapering to a waist near the midpoint of the slot.

Claim 30

Dependent Claim 126 words

A rotor assembly for a permanent magnet dynamoelectric machine comprising: a set of laminations secured together to form a rotor body, each lamination having at least a first magnet slot therein, said first magnet slots of the various laminations being substantially identical, the laminations being rotationally skewed with respect to each other; a rotor shaft disposed along the longitudinal axis of the rotor body; and a generally rectangular permanent magnet disposed in the first magnet slot; the first magnet slot of each lamination being shaped so as to receive said rectangular permanent magnet through all the skewed laminations with a minimum air gap; the magnet slot being generally wider at each end of the slot and tapering to a waist near the midpoint of the slot.

Claim 31

Dependent Claim 79 words

The rotor assembly as set forth in claim 24 wherein first and second lines intersecting and terminating at the waist of the slot define one side of the slot and third and fourth lines intersecting and terminating at the waist of the slot define the opposite side of the slot, said first and third lines being parallel and on opposite sides of the waist and the second and fourth lines being parallel and on opposite sides of the waist.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1993-07-02	1994-01-01	1994-07-03	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1997-07-02	1998-01-01	1998-07-03	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2001-07-02	2002-01-01	2002-07-03	$7700.00	Window Closed / Lapsed

Laminated assemblies with in situ molded magnets

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