# US 2018/0323666 A1 · Interior permanent magnet rotor hubs

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- Number: US 2018/0323666 A1
- Document ID: US20180323666A1
- Status: Published application
- Kind: A1
- Application number: 16/031,841
- Filed: 2018-07-10
- Published: 2018-11-08
- Earliest claimed: 2016-04-13
- Assignees: Hamilton Sundstrand Corporation
- Applicants: Hamilton Sundstrand Corporation
- Inventors: Dhaval Patel; Andreas C. Koenig
- Web page: https://patentgrep.com/patent/US20180323666A1

## CPC

- H02K 1/274: the rotor consisting of two or more circumferentially positioned magnets
- H02K 1/02: characterised by the magnetic material
- H02K 1/276: Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
- H02K 15/03: having permanent magnets
- Y10T 29/49012: Rotor
- H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53})
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A permanent magnet machine includes a rotor including a rotor hub and a plurality of permanent magnets embedded in the rotor in a circumferential pattern. The rotor includes a respective bridge between each circumferentially adjacent pair of the permanent magnets. Each bridge is of a different material than that of the rotor hub, and the rotor hub and bridges are integral with one another.

## Claims

### Claim 1

A method of producing a permanent magnet machine comprising:
additively manufacturing a rotor including a rotor hub and a plurality of bridges radially outward of the rotor hub, wherein each bridge is of a different material than that of the rotor hub, and wherein the rotor hub and bridges are additively manufactured integral with one another.

### Claim 2 (depends on 1)

A method as recited in claim 1, wherein additively manufacturing the rotor includes building the rotor up around a plurality of magnets so the magnets become embedded in the rotor.

### Claim 3 (depends on 2)

A method as recited in claim 2, wherein building up the rotor around the magnets includes building the rotor up around the magnets with no gap between the magnets and the rotor.

### Claim 4 (depends on 1)

A method as recited in claim 1, wherein additively manufacturing the rotor includes building the rotor up without any magnets in place, and further comprising:
embedding a plurality of magnets in the rotor after the rotor has been additively manufactured.

### Claim 5 (depends on 1)

A method as recited in claim 1, wherein embedding the magnets in the rotor includes embedding the magnets so there is no gap between the rotor and the magnets.

### Claim 6 (depends on 1)

A method as recited in claim 1, wherein additively manufacturing the rotor includes forming the bridges are of material with lower magnetic permeability than that of the rotor hub.

### Claim 7 (depends on 1)

A method as recited in claim 1, wherein additively manufacturing the rotor includes forming the rotor with a respective transition region between each bridge and the rotor hub wherein the material of the bridge transitions into that of the rotor hub.

### Claim 8 (depends on 7)

A method as recited in claim 7, further comprising embedding permanent magnets in the rotor in a circumferential pattern with a respective one of the bridges between each circumferentially adjacent pair of the permanent magnets, wherein additively manufacturing the rotor includes forming the rotor with a single respective transition region circumferentially between each circumferentially adjacent pair of the permanent magnets.

### Claim 9 (depends on 1)

A method as recited in claim 1, wherein additively manufacturing the rotor includes forming the rotor with a respective pole portion radially outward of each permanent magnet and circumferentially between each pair of circumferentially adjacent ones of the bridges, wherein the pole portion is of a different material from the bridges.

### Claim 10 (depends on 9)

A method as recited in claim 9, wherein the pole portions and the rotor hub are formed of a common material.

### Claim 11 (depends on 9)

A method as recited in claim 9, wherein additively manufacturing the rotor includes forming the rotor with the material of each bridge transitioning into that of the respective pole. portions.

### Claim 12 (depends on 11)

A method as recited in claim 11, wherein there are two respective transition regions formed circumferentially between each pair of circumferentially adjacent pair of the pole portions.