Low porosity and consistent metallurgical bonding for hybrid motor rotors

A molded rotor stack assembly, comprising:

• a rotor stack having multiple metal plates individually including:
• multiple elongated slots oriented radially outward from a plate longitudinal central axis toward a plate outer perimeter wall;
• multiple openings individually positioned proximate to one of the slots and directed outwardly through the plate outer perimeter wall;
• and
• multiple runners individually opening into at least one of opposed ends of each of the slots;
• the runners between successive plates aligned to create multiple aligned passages from end-to-end of the rotor stack;
• multiple bars of a conductive material individually extended through aligned ones of the slots of the multiple plates;
• and
• an aluminum material forced in molten form into the multiple aligned passages and extending through the multiple aligned passages to each of the plates and from each of the multiple aligned passages extending radially outwardly into the slots to surround the bars positioned in the slots.

A method for molding a rotor stack assembly, comprising:

• forming multiple steel plates by stamping multiple elongated slots into the plates oriented radially outward from a plate longitudinal central axis toward a plate outer perimeter wall;
• positioning openings in the plates individually proximate to one of the slots and directed outwardly through the plate outer perimeter wall;
• and
• creating multiple runners extending through each plate individually opening into one of opposed ends of the slots;
• aligning the plates with individual runners aligned with one of the runners of a next successive one of the plates to create multiple aligned passages from end-to-end of the rotor stack;
• inserting multiple bars of a conductive material individually through aligned ones of the slots of each of the multiple plates;
• and
• injecting a molten aluminum material into the multiple aligned passages and extending to each of the plates and from each of the multiple aligned passages radially outwardly into each of the slots to surround the bars positioned in the slots.