Rotor core with load bearing polymer and insert

A rotor core for an electric machine, comprising:

• a core stack including a plurality of lamination plates, wherein each lamination plate includes a plurality of apertures formed therein, and wherein the plurality of apertures of each of the lamination plates are axially aligned and each define a plurality of axial magnet slots extending through the core stack shaped to receive a corresponding permanent magnet insert therein and a slot extending through the core stack and shaped to receive a corresponding insert;
• at least one insert received by the slot of the rotor core that provides radial structural stability to the plurality of lamination plates to prevent portions of the plurality of lamination plates adjacent the plurality of axial magnet slots from flexing due to radial forces exerted on the plurality of lamination plates during operation of the rotor core, wherein the insert includes a first pair of hooked tabs and a second pair of hooked tabs disposed on opposing sides of the insert;
• and
• a load bearing polymer disposed within the aperture of the rotor core, wherein the load bearing polymer provides contact between the insert and the lamination plates.

A rotor core for an electric machine, comprising:

• a core stack including a plurality of lamination plates, wherein each lamination plate includes a plurality of apertures formed therein, and wherein the plurality of apertures of each of the lamination plates are axially aligned and each define a plurality of axial magnet slots extending through the core stack shaped to receive a corresponding permanent magnet insert therein and a slot extending through the core stack and shaped to receive a corresponding insert, and wherein the rotor core defines an inner flux guide, a middle flux guide, and an outer flux guide, and wherein the middle flux guide defines a first retention tab that projects inwardly towards the inner flux guide, and the outer flux guide defines a second retention tab that projects outwardly towards the middle flux guide;
• at least one insert received by the slot of the rotor core that provides radial structural stability to the plurality of lamination plates to prevent portions of the plurality of lamination plates adjacent the plurality of axial magnet slots from flexing due to radial forces exerted on the plurality of lamination plates during operation of the rotor core;
• and
• a load bearing polymer disposed within the aperture of the rotor core, wherein the load bearing polymer provides contact between the insert and the lamination plates.