# US 12,119,714 B1 · Rotor for a high speed electrical machine

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- Number: US 12,119,714 B1
- Document ID: US12119714B1
- Status: Granted
- Kind: B1
- Application number: 18/220,893
- Filed: 2023-07-12
- Granted: 2024-10-15
- Earliest claimed: 2019-11-19
- Assignees: The United States of America as represented by the Secretary of the Air Force
- Applicants: Government of the United States, as represented by the Secretary of the Air Force
- Inventors: Zafer Turgut
- Web page: https://patentgrep.com/patent/US12119714B1

## CPC

- H02K 1/28: Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures
- H02K 1/30: using intermediate parts, e.g. spiders
- H02K 1/2781: Magnets shaped to vary the mechanical air gap between the magnets and the stator
- H02K 15/03: having permanent magnets
- H02K 7/003: {Couplings; Details of shafts (means for mounting rotors on shafts H02K1/28)}
- H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53})

## Abstract

A unique rotor assembly for an electrical machine is disclosed herein. The rotor assembly includes a shaft having an axis of rotation extending within the electrical machine. A central support is connected to the shaft at an intermediate position and a pair of opposing end plates are configured to clamp a plurality of laminate plates therebetween. The laminate plates and a sidewall of the end plates have a non-linear cross-sectional shape such that radial loading due to centrifugal force is transmitted from the laminate plates to the end plates during operation.

## Claims

### Claim 1

A Method comprising:
forming a housing for an electrical machine;
positioning a shaft in the housing along an axis of rotation between first and second ends;
winding a stator within the housing;
supporting a rotor assembly radially inward of the stator;
connecting a central support to the shaft at an intermediate position between the first and second ends;
connecting first and second end plates to the shaft at the opposing first and second ends thereof;
connecting a plurality of laminate plates to the shaft between the central support and the first and second end plates; and
restricting radial growth of the laminate plates with first and second end plates; and
wherein restricting the radial growth includes forming the laminate plates in a non-linear cross sectional shape.

### Claim 2 (depends on 1)

The method of claim 1, wherein restricting the radial growth includes forming the laminate plates with a non-orthogonal angle extending radially outward from the shaft relative to the axis of rotation.

### Claim 3 (depends on 1)

The method of claim 1, wherein restricting the radial growth includes forming the laminate plates in an arcuate concave shape.

### Claim 4 (depends on 1)

The method of claim 1, wherein restricting the radial growth includes forming a first sidewall of each of the end plates with a non-linear shape substantially equivalent to a non-linear cross sectional shape of the laminate plates.

### Claim 5 (depends on 4)

The method of claim 4, wherein each of the end plates includes a second sidewall having a different shape than that of the first sidewall.

### Claim 6 (depends on 4)

The method of claim 4, wherein the first sidewall of each of the end plates includes a concave arcuate shape.

### Claim 7 (depends on 1)

The method of claim 1, wherein the central support includes opposing sidewalls having a non-linear shape corresponding to the non-linear cross sectional shape of the laminate plates.

### Claim 8 (depends on 7)

The method of claim 7, wherein the opposing side walls of the central support have a convex arcuate shape.

### Claim 9 (depends on 7)

The method of claim 7, wherein the opposing side walls of the central support includes a non-orthogonal angle extending radially outward from the shaft relative to the axis of rotation.

### Claim 10 (depends on 1)

The method of claim 1, further comprising positioning permanent magnets on a perimeter end of one or more of the laminate plates.

### Claim 11

A method comprising:
positioning a plurality of laminate plates on a rotatable shaft within an electrical machine;
positioning a central support between the plurality of laminate plates on the shaft;
clamping the laminate plates together with a pair of end plates at either end of the shaft;
wherein a portion of the laminate plates is positioned radially inward of a portion of the end plates;
transmitting radial loads from the laminate plates to the end plates during operation of the electrical machine;
wherein a shape of the laminate plates, a shape of the central support and a shape of the end plates cooperate to form a nested configuration; and
wherein the nesting includes one of a concave curved portion and a non-orthogonal angle extending radially outward from the shaft relative to the axis of rotation.

### Claim 12 (depends on 11)

The method of claim 11, further comprising positioning permanent magnets on a perimeter end of one or more of the laminate plates.