# US 11,444,520 B1 · Method for motor manufacturing using a clip system

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- Number: US 11,444,520 B1
- Document ID: US11444520B1
- Status: Granted
- Kind: B1
- Application number: 17/529,951
- Filed: 2021-11-18
- Granted: 2022-09-13
- Earliest claimed: 2021-11-18
- Assignees: Beta Air, LLC
- Applicants: Beta Air, LLC
- Inventors: Brandon White; Stephen Widdis
- Web page: https://patentgrep.com/patent/US11444520B1

## CPC

- H02K 15/14: Casings; Enclosures; Supports
- H02K 15/03: having permanent magnets
- Y10T 29/49009: Dynamoelectric machine
- H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53})
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A method for motor manufacturing using a clip system is illustrated. The method includes sliding a plurality of magnets onto a vertical dowel hoop, wherein the plurality of magnets are stacked on each dowel, attaching a first plate to the top of the vertical dowel hoop and a second plate to the bottom of the vertical dowel hoop, wherein the plates compress the plurality of magnets on each vertical dowel, and curing the combination of the first plate, the second plate, the plurality of magnets and the vertical dowel hoop.

## Claims

### Claim 1

A motor manufacturing method using a clip system for an electric aircraft, the method comprising:
receiving a vertical dowel hoop, comprising a plurality of vertical dowels about a circumference of the vertical dowel hoop;
sliding a plurality of magnets onto the vertical dowel hoop, wherein the plurality of magnets are stacked on each dowel of the plurality of dowels;
attaching a first plate to the top of the vertical dowel hoop and a second plate to the bottom of the vertical dowel hoop, wherein the plates compress the plurality of magnets on each vertical dowel; and
curing the combination of the first plate, the second plate, the plurality of magnets and the vertical dowel hoop.

### Claim 2 (depends on 1)

The method of claim 1, wherein the vertical dowels are rigidly attached to the hoop in order to hold the plurality of magnets in place.

### Claim 3 (depends on 1)

The method of claim 1, wherein the vertical dowels are rigidly attached to the circumference of the hoop.

### Claim 4 (depends on 1)

The method of claim 1, wherein the vertical dowel hoop is welded.

### Claim 5 (depends on 1)

The method of claim 1, wherein each magnet of the plurality of magnets has a hole through a center of the magnet, the hole shaped to slidably admit a dowel.

### Claim 6 (depends on 1)

The method of claim 1 further comprising stacking two or more magnets of the plurality of magnets on each dowel.

### Claim 7 (depends on 6)

The method of claim 6, wherein the layer of glue is an adhesive that becomes rigid during curing.

### Claim 8 (depends on 1)

The method of claim 1 further comprising applying a layer of glue between adjacent magnets of the plurality of magnets.

### Claim 9 (depends on 1)

The method of claim 1 further comprising locking the plurality of magnets into place using the first and second plates.

### Claim 10 (depends on 1)

The method of claim 1, wherein the plates lock together to compress the plurality of magnets on each dowel.

### Claim 11 (depends on 1)

The method of claim 1 further comprising placing the first plate on top of the stack of the plurality of magnets.

### Claim 12 (depends on 1)

The method of claim 1 further comprising placing the second plate beneath the stack of the plurality of magnets.

### Claim 13 (depends on 1)

The method of claim 1, wherein the first plate and second plate are made out of any material with a tensile strength of more than 200 MPa.

### Claim 14 (depends on 13)

The method of claim 13, wherein once cured, the combination of the first plate, the second plate, the plurality of magnets and the vertical dowel hoop are removed from oven.

### Claim 15 (depends on 1)

The method of claim 1, wherein curing comprises heating the combination of the first plate, the second plate, the plurality of magnets and the vertical dowel hoop in an oven.

### Claim 16 (depends on 1)

The method of claim 1, wherein once cured, the first plate and the second plate are unlocked and removed from the plurality of magnets and vertical dowel hoop, such that the magnets remain in a fixed position on the vertical dowel hoop.

### Claim 17 (depends on 1)

The method of claim 1, wherein the motor being manufactured is configured to propel to an electric aircraft.

### Claim 18 (depends on 1)

The method of claim 1, wherein the curing occurs at least at 200 degrees Celsius.

### Claim 19 (depends on 1)

The method of claim 1, wherein the motor is electrically connected to and electrically powered by at least a battery pack in the electric aircraft.

### Claim 20 (depends on 1)

The method of claim 1, wherein the motor includes a motor controller, including an inverter configured to power the motor.