# US 11,909,270 B2 · Electric motor with permanent magnets abutted by tabs in lamination cavities

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- Number: US 11,909,270 B2
- Document ID: US11909270B2
- Status: Granted
- Kind: B2
- Application number: 17/303,516
- Filed: 2021-06-01
- Published: 2021-09-16
- Granted: 2024-02-20
- Earliest claimed: 2019-06-26
- Assignees: Atieva, Inc.
- Applicants: Atieva, Inc.
- Inventors: Emad Dlala
- Web page: https://patentgrep.com/patent/US11909270B2

## CPC

- H02K 1/2766: {having a flux concentration effect}
- H01F 1/083: {in a bonding agent}
- H01F 1/086: {sintered}
- H01F 1/10: non-metallic substances, e.g. ferrites {, e.g. [(Ba,Sr)O(Fe2O3)6] ferrites with hexagonal structure}
- H02K 1/02: characterised by the magnetic material
- H02K 1/26: Rotor cores with slots for windings
- H02K 1/28: Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
- H02K 3/04: Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
- H02K 15/03: having permanent magnets
- H02K 17/16: having rotors with internally short-circuited windings, e.g. cage rotors
- H02K 21/16: having annular armature cores with salient poles (with homopolar co-operation H02K21/20)
- H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53})
- H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES

## Abstract

A hybrid rotor assembly is provided. The assembly utilizes two different types of magnets within the lamination cavities of the lamination stack: sintered permanent magnets and bonded magnets.

## Claims

### Claim 1

An electric motor comprising:
a stator;
a rotor assembly comprising:
a hollow rotor shaft;
a differential gear assembly contained in the hollow rotor shaft;
a lamination stack mounted on the hollow rotor shaft;
a plurality of lamination cavities within the lamination stack, the lamination stack defining a plurality of tabs that extend into the plurality of lamination cavities; and
a plurality of permanent magnets contained within the plurality of lamination cavities, wherein the plurality of tabs abut the plurality of permanent magnets; and
a first planetary assembly positioned at a first end of the rotor assembly, and a second planetary assembly positioned at a second end of the rotor assembly, wherein the first and second planetary assemblies and the differential gear assembly are coaxially aligned.

### Claim 2 (depends on 1)

The electric motor of claim 1, wherein the lamination stack comprises lamination sections, each of the lamination sections comprising a plurality of lamination discs, wherein the lamination sections are skewed relative to each other.

### Claim 3 (depends on 2)

The electric motor of claim 2, wherein the lamination stack comprises four lamination sections.

### Claim 4 (depends on 1)

The electric motor of claim 1, wherein the plurality of lamination cavities are configured as a plurality of pairs, wherein each pair corresponds to a pole of the electric motor.

### Claim 5 (depends on 4)

The electric motor of claim 4, wherein each of the plurality of pairs is arranged in a V-shaped configuration.

### Claim 6 (depends on 1)

The electric motor of claim 1, wherein the plurality of permanent magnets comprise a material selected from the group of materials consisting of ferrite, ceramic, alnico, samarium cobalt, neodymium and neodymium-iron-boron.

### Claim 7 (depends on 1)

The electric motor of claim 1, wherein the electric motor is selected from the group consisting of an interior permanent magnet motor, a permanent magnet synchronous motor, an interior permanent magnet brushless DC motor, and an interior permanent magnet synchronous reluctance motor.

### Claim 8 (depends on 1)

The electric motor of claim 1, wherein each of the permanent magnets is cuboid shaped.

### Claim 9 (depends on 1)

The electric motor of claim 1, wherein at least one of the plurality of lamination cavities further comprises a void not filled by any of the plurality of permanent magnets.

### Claim 10 (depends on 9)

The electric motor of claim 9, wherein the void is filled other than by any of the plurality of permanent magnets.

### Claim 11 (depends on 10)

The electric motor of claim 10, wherein the void is filled by a resin.

### Claim 12 (depends on 11)

The electric motor of claim 11, wherein the resin comprises an epoxy thermosetting resin.