# US 12,215,693 B2 · Permanent magnet rotor for an axial flux motor

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- Number: US 12,215,693 B2
- Document ID: US12215693B2
- Status: Granted
- Kind: B2
- Application number: 17/789,769
- Filed: 2021-01-08
- Published: 2023-02-09
- Granted: 2025-02-04
- Earliest claimed: 2020-01-09
- Assignees: The Gates Corporation
- Applicants: Gates Corporation
- Inventors: Vigel Russalian
- Web page: https://patentgrep.com/patent/US12215693B2

## CPC

- F04D 13/064: {Details of the magnetic circuit}
- B22F 5/10: of articles with cavities or holes, not otherwise provided for in the preceding subgroups
- F01P 5/10: Pumping liquid coolant; Arrangements of coolant pumps
- F01P 5/12: Pump-driving arrangements
- F04D 1/00: Radial-flow pumps, e.g. centrifugal pumps; Helico-centrifugal pumps (adapted for pumping specific fluids F04D7/00; priming or boosting F04D9/00)
- F04D 13/026: {Details of the bearings}
- F04D 13/0646: {the hollow pump or motor shaft being the conduit for the working fluid}
- F04D 13/0666: {the motor being of the plane gap type}
- F04D 29/026: {especially adapted for liquid pumps}
- F04D 29/22: specially for centrifugal pumps
- H02K 1/2795: the rotor consisting of two or more circumferentially positioned magnets
- H02K 15/03: having permanent magnets
- C22C 2202/02: Magnetic
- F01P 2005/125: {Driving auxiliary pumps electrically}
- F04D 29/049: Roller bearings
- F05D 2230/22: by sintering
- F04D: NON-POSITIVE-DISPLACEMENT PUMPS (engine fuel-injection pumps F02M; ion pumps H01J41/12; electrodynamic pumps H02K44/02)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- F01P: COOLING OF MACHINES OR ENGINES IN GENERAL; COOLING OF INTERNAL-COMBUSTION ENGINES (arrangements in connection with cooling of propulsion units in vehicles B60K11/00; heat-transfer, heat-exchange or heat-storage materials C09K5/00; {cooling of gas-turbine engines F02C7/12}; heat exchange in general, radiators F28)
- H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53})
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS

## Abstract

An axial flux motor water pump comprising a housing, a cover attached to the housing, a stator mounted within the housing, the stator comprising a plurality of stator poles mounted in a ring, each stator pole comprising an electric wire winding, a rotor journaled to the housing in cooperating relation to the stator on a single bearing, an impeller fixed to an end of the rotor, a plurality of magnets mounted to an end of the rotor in cooperative relation to the stator poles, a seal between the rotor and housing whereby the stator and magnets are in a dry zone, the stator enrobed in thermal potting within the housing; and power electronics contained in the cover. The rotor portion of the rotor may be manufactured in a sintering process.

## Claims

### Claim 1

An axial flux motor water pump comprising:
a housing;
a cover attached to the housing;
a stator mounted within the housing, the stator comprising a plurality of stator poles mounted in a ring, each stator pole comprising an electric wire winding;
a rotor journaled to the housing in cooperating relation to the stator on a single bearing, the rotor comprising a rotor shaft having a rotational axis and either a plurality of magnets or a ring magnet, wherein the plurality of magnets or the ring magnet are mounted on a frame on a first end of the rotor shaft in cooperative relation to the stator poles,
an impeller fixed to a second end of the rotor shaft;
a seal between the rotor and the housing whereby the stator and the plurality of magnets or the ring magnet are in a dry zone, the plurality of magnets or the ring magnet and the frame being manufactured in a sintering process comprising:
adding a first material to a die,
adding a second material to the die above the first material,
compressing the first material and the second material within the die, and
magnetizing the second material;
a condensate chamber and reservoir comprising a vent hole and a drain hole, wherein the condensate chamber and reservoir is positioned to collect any fluid that may leak past the seal, and the vent and drain hole are open to ambient;
the stator enrobed in thermal potting within the housing; and
power electronics contained in the cover.

### Claim 2 (depends on 1)

The axial flux motor water pump as in claim 1, wherein the electric wire winding comprises a flat wire.

### Claim 3 (depends on 1)

The axial flux motor water pump as in claim 1, wherein the electric wire winding comprises a round wire.

### Claim 4 (depends on 1)

The axial flux motor water pump as in claim 1, wherein the rotor is journaled on a double row ball bearing.

### Claim 5 (depends on 1)

The axial flux motor water pump as in claim 1, wherein the impeller is cantilever mounted to the rotor.

### Claim 6 (depends on 1)

The axial flux motor water pump as in claim 1, wherein, in the direction of the rotational axis, the stator is positioned between the impeller and the plurality of magnets or the ring magnet and the frame.