# US 11,909,268 B2 · Integrated rotor

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- Number: US 11,909,268 B2
- Document ID: US11909268B2
- Status: Granted
- Kind: B2
- Application number: 17/198,424
- Filed: 2021-03-11
- Published: 2022-09-15
- Granted: 2024-02-20
- Earliest claimed: 2021-03-11
- Assignees: ZF Active Safety US Inc.
- Applicants: ZF Active Safety US Inc.
- Inventors: Irfan Bhatti
- Web page: https://patentgrep.com/patent/US11909268B2

## CPC

- H02K 1/278: Surface mounted magnets; Inset magnets
- H02K 1/2781: Magnets shaped to vary the mechanical air gap between the magnets and the stator
- H02K 1/28: Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
- H02K 7/04: Balancing means
- H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53})

## Abstract

A rotor assembly for a motor includes at least one magnet, a magnet support having an end region, a rotor shaft and an over-molded body affixed to the at least one magnet and the magnet support. The over-molded body includes a first end and a second end. The rotor shaft may be disposed proximate to the first end of the over-molded body and the second end of the over-molded body is proximate to the end region of the magnet support.

## Claims

### Claim 1

A rotor assembly for a motor comprising:
a rotor shaft;
a magnet support having an end region configured to engage with one of a plurality of yokes;
at least one magnet disposed on the magnet support; and
an over-molded body having a first end and a second end, the over-molded body being over-molded directly onto the at least one magnet and the magnet support to secure the at least one magnet to the magnet support;
wherein the rotor shaft is disposed proximate to the first end of the over-molded body and the second end of the over-molded body is proximate to the end region of the magnet support.

### Claim 2 (depends on 1)

The rotor assembly according to claim 1 wherein the over-molded body couples the at least one magnet, magnet support and rotor shaft to each other.

### Claim 3 (depends on 1)

The rotor assembly according to claim 1 wherein the magnet support is affixed to the rotor shaft and the over-molded body is configured to couple the at least one magnet to the magnet support.

### Claim 4 (depends on 3)

The rotor assembly according to claim 3 wherein the magnet support is integral to the rotor shaft.

### Claim 5 (depends on 2)

The rotor assembly according to claim 2 further comprising at least one protrusion defined in the over-molded body and the at least one protrusion is configured to balance the rotor assembly.

### Claim 6 (depends on 3)

The rotor assembly according to claim 3 further comprising at least one protrusion defined in the over-molded body and the at least one protrusion is configured to balance the rotor assembly.

### Claim 7 (depends on 4)

The rotor assembly according to claim 4 further comprising at least one protrusion defined in the over-molded body and the at least one protrusion is configured to balance the rotor assembly.

### Claim 8 (depends on 5)

The rotor assembly according to claim 5 wherein the at least one protrusion is defined on an outer surface of the over-molded body.

### Claim 9 (depends on 6)

The rotor assembly according to claim 6 wherein the at least one protrusion is defined on an outer surface of the over-molded body.

### Claim 10 (depends on 7)

The rotor assembly according to claim 7 wherein the at least one protrusion is defined on an outer surface of the over-molded body.

### Claim 11

A rotor assembly for a motor, comprising:
a rotor shaft;
a magnet support having an end region configured to engage with one of a plurality of yokes;
at least one magnet disposed on the magnet support and secured to the magnet support via an adhesive; and
an over-molded body having a first end and a second end, the over-molded body being over-molded onto the at least one magnet and the magnet support such that the at least one magnet is secured to the magnet support via the over-molded body and the adhesive;
wherein the rotor shaft is disposed proximate to the first end of the over-molded body and the second end of the over-molded body is proximate to the end region of the magnet support.

### Claim 12 (depends on 1)

A rotor assembly according to claim 1 for a motor, comprising:
a rotor shaft;
a magnet support having an end region configured to engage with one of a plurality of yokes;
at least one magnet disposed on the magnet support; and
an over-molded body having a first end and a second end, the over-molded body being over-molded onto the at least one magnet and the magnet support to secure the at least one magnet to the magnet support;
wherein the at least one magnet is affixed to the magnet support via an adhesive prior to the over-molded body being over-molded onto the at least one magnet and magnet support; and
wherein the rotor shaft is disposed proximate to the first end of the over-molded body and the second end of the over-molded body is proximate to the end region of the magnet support.