US 12,119,708 B2Granted

Electrical machine having shaped soft metal composite components with axial and radial airgaps

AssigneeElemental Motors, LLC

InventorDavid Calley

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Abstract

An electric machine, which may operate as an electric motor or generator, that address performance and manufacturing shortcomings in various motor design approaches particularly transverse flux, axial and radial flux motors with higher torque, higher RPM, and lower core losses and lower cogging. An exemplary electric machine incorporates shape monolithic components such as the armature teeth or connector ring, armature ring, concentrator teeth or concentrator ring formed by Soft metal Composite (SMC). Magnets may be configured between the concentrator teeth to form a magnet ring having a plurality of magnetic poles. The armature flux paths may be shared between phases. The air gaps may be axial and extend between armature teeth and concentrator teeth and the magnetic poles configured between the concentrator teeth. The armature, concentrator teeth and magnetic poles may extend radially and alternate along the axial axis of the electric machine, producing axial and/or radial airgaps.

Claims40

Dependent claims

A multi phase transverse flux electric machine comprising:

a) a first magnet ring comprising a plurality of magnets and a plurality of concentrators;
b) a second magnet ring comprising a plurality of magnets and a plurality of concentrators;
c) a single set of shared armature teeth extending from a second armature connector ring and configured between said first magnet ring and said second magnet rings, said shared armature teeth formed of shaped soft metal composite (SMC);
wherein magnetic flux from the first magnet ring and the second magnet ring flow into said armature teeth of the second armature connector ring;
and
d) a first armature connector ring axially displaced on a first side of the first magnet ring, and having armature teeth formed of shaped soft metal composite (SMC);
wherein said second armature connector ring is configured between the first and second magnet rings;
wherein the armature teeth of each of the first and second armature connector rings extend from the respective armature connector ring;
wherein the armature teeth of each of the first and second armature connector rings extend radially from the respective armature connector ring to a tooth tip;
e) a coil between the first armature connector ring and the second armature connector ring;
wherein the armature teeth of the second connector ring have opposing axial airgap surfaces forming an airgap with the first magnet ring and the second magnet ring;
wherein the armature teeth of each of the first and second armature connector rings are continuously tapered along the axial air gap surfaces from the armature connector ring to the tooth tip;
wherein the magnetic flux flows from the first magnet ring into the armature teeth of the second armature connector, then radially to the second armature connector ring, then axially around said central coil, then back to said first magnet ring to produce transverse flux.

10 more elements

A multi phase transverse flux electric machine comprising:

a) a first magnet ring comprising a plurality of magnets and a plurality of concentrators;
b) a second magnet ring comprising a plurality of magnets and a plurality of concentrators;
c) a single set of shared armature teeth extending from a second armature connector ring and configured between said first magnet ring and said second magnet rings, said shared armature teeth formed of shaped soft metal composite (SMC);
wherein magnetic flux from the first magnet ring and the second magnet ring flow into said armature teeth of the second armature connector ring;
and
d) a first armature connector ring axially displaced on a first side of the first magnet ring, and having armature teeth formed of shaped soft metal composite (SMC);
wherein said second armature connector ring is configured between the first and second magnet rings;
wherein the armature teeth of each of the first and second armature connector rings extend from the respective armature connector ring;
e) a central coil configured around the second connector ring;
wherein the armature teeth of each of the first and second armature connector rings extend radially from the respective armature connector ring to a tooth tip;
wherein the magnetic flux flows from the first magnet ring into the armature teeth of the second armature connector, then radially to the second armature connector ring, then axially around said central coil, then back to said first magnet ring to produce transverse flux;
wherein each of the armature teeth of the second armature connector ring has a first radial gap extension forming a radial airgap with the first magnet ring and a second radial airgap extension forming a radial airgap with the second magnet ring.

9 more elements

A multi phase transverse flux electric machine comprising:

a) a first magnet ring comprising a plurality of magnets and a plurality of concentrators;
b) a second magnet ring comprising a plurality of magnets and a plurality of concentrators;
c) a single set of shared armature teeth extending from a second armature connector ring and configured between said first magnet ring and said second magnet rings, said shared armature teeth formed of shaped soft metal composite (SMC);
wherein magnetic flux from the first magnet ring and the second magnet ring flow into said armature teeth of the second armature connector ring;
and
d) a first armature connector ring axially displaced on a first side of the first magnet ring, and having armature teeth formed of shaped soft metal composite (SMC);
wherein said second armature connector ring is configured between the first and second magnet rings;
wherein the armature teeth of each of the first and second armature connector rings extend from the respective armature connector ring;
e) a central coil configured around the second armature connector ring;
wherein the armature teeth of each of the first and second armature connector rings extend radially from the respective armature connector ring to a tooth tip;
wherein the magnetic flux flows from the first magnet ring into the armature teeth of the second armature connector, then radially to the second armature connector ring, then axially around said central coil, then back to said first magnet ring to produce transverse flux;
wherein each of the first magnet ring and the second magnet ring comprise:
i) a concentrator connector ring wherein the plurality of concentrators are a plurality of concentrator teeth extending from said concentrator connector ring;
and
wherein said plurality of magnets are configured between adjacent concentrator teeth;
wherein the concentrator connector ring and plurality of concentrator teeth is a monolith component formed of shaped soft metal composite;
wherein one of the armature rings and the first and second magnet rings rotates about an axial axis and wherein the armature teeth extend radially with respect to the axial axis;
and
wherein an axial airgap is formed between the armature teeth and the concentrator teeth;
whereby magnetic flux moves across the axial airgap.

17 more elements

Dependencies are inferred from the claim text.

Facts

Application: 17/790,722Filed 18 Mar 2021 · us provisional application
Priority: 18 Mar 2020
Published: US 2023/0069099 A12 Mar 2023
Granted: 15 Oct 2024
Term ends: Not estimatedThe source records don’t support an estimate.

Classification14 codes

H02K 1/148
Consisting of a generally annular yoke with salient poles: sectional cores
H02K 1/02
Details of the magnetic circuit: characterised by the magnetic material
H02K 1/145
Stator cores with salient poles: having an annular coil, e.g. of the claw-pole type
H02K 1/16
Stationary parts of the magnetic circuit: stator cores with slots for windings

Family

Application63/100,541Us provisional application · filed 18 Mar 2020
US 2023/0069099 A1Pre-grant publication · published 2 Mar 2023
US 12,119,708 B2This patent

From the US filing history. Foreign family members aren’t listed.

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