# US 2026/0039162 A1 · Wedge with auxiliary tool method for mechanical magnet retention in electric machines > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2026/0039162 A1 - Document ID: US20260039162A1 - Status: Published application - Kind: A1 - Application number: 18/788,398 - Filed: 2024-07-30 - Published: 2026-02-05 - Earliest claimed: 2024-07-30 - Assignees: Fca US LLC - Applicants: Fca US LLC - Inventors: Reza Ghafoori-Ahangor; Dhafar Al-Ani - Web page: https://patentgrep.com/patent/US20260039162A1 ## CPC - H02K 1/28: Means for mounting or fastening rotating magnetic parts on to, or to, the rotor structures - H02K 1/276: Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM] - H02K 1/2766: {having a flux concentration effect} - H02K 15/03: having permanent magnets - B60K 1/00: Arrangement or mounting of electrical propulsion units (B60K7/00 takes precedence; arrangement or mounting of plural diverse prime-movers for mutual or common propulsion B60K6/00) - H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53}) - B60K: ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES ## Abstract An electric machine for powering an electric vehicle includes a rotor, a plurality of first rotor laminations, and a plurality of second rotor laminations. The rotor is configured to rotate relative to a stator to drive a rotor shaft and at least one drive wheel of the electric vehicle, the rotor defining at least a first rotor slot configured to receive a magnet therein. The plurality of first rotor laminations stacked upon each other each having a first pattern. The plurality of second rotor laminations each have a second pattern, distinct from the first pattern, and have a retention mechanism defined thereon. The plurality of second rotor laminations are configured to deflect upon advancement of an auxiliary tool into the plurality of second rotor laminations at the respective retention mechanisms, the respective retention mechanisms deflecting into the magnet creating a retention load retaining the magnet within the rotor slot. ## Claims ### Claim 1 An electric machine for powering an electric vehicle, the electric machine comprising: a rotor configured to rotate relative to a stator to drive a rotor shaft and at least one drive wheel of the electric vehicle, the rotor defining at least a first rotor slot configured to receive a magnet therein; a plurality of first rotor laminations stacked upon each other each having a first pattern; and a plurality of second rotor laminations each having a second pattern, distinct from the first pattern, the plurality of second rotor laminations each having a retention mechanism defined thereon; wherein the plurality of second rotor laminations are configured to deflect upon advancement of an auxiliary tool into the plurality of second rotor laminations at the respective retention mechanisms, the respective retention mechanisms deflecting into the magnet creating a retention load retaining the magnet within the rotor slot. ### Claim 2 (depends on 1) The electric machine of claim 1, wherein the auxiliary tool comprises a first auxiliary tool, wherein the plurality of first rotor laminations do not deflect upon the advancement of the first auxiliary tool into the plurality of second rotor laminations. ### Claim 3 (depends on 2) The electric machine of claim 2, wherein the plurality of first rotor laminations outnumber the plurality of second laminations. ### Claim 4 (depends on 1) The electric machine of claim 1, wherein the second rotor lamination defines an edge at the rotor slot, wherein the retention mechanism deflects causing the retention load of the magnet against the edge. ### Claim 5 (depends on 1) The electric machine of claim 1, wherein the auxiliary tool is configured to be advanced in a direction parallel to the rotor slot and into the respective retention mechanisms. ### Claim 6 (depends on 1) The electric machine of claim 1, wherein a second rotor lamination of the plurality of second rotor laminations is interleaved between multiple first rotor laminations of the plurality of first rotor laminations. ### Claim 7 (depends on 1) The electric machine of claim 1, wherein the plurality of second rotor laminations align and deflect upon the advancement, wherein the first rotor laminations do not deflect upon the advancement of the auxiliary tool. ### Claim 8 A method for assembling a rotor configured for use in an electric motor for powering and electric vehicle, the rotor configured to rotate relative to a stator to drive a rotor shaft and at least one drive wheel of the electric vehicle, the rotor defining at least a first rotor slot configured to receive a magnet therein, the method comprising: arranging a plurality of first rotor laminations stacked upon each other, each having a first pattern; arranging a second rotor lamination between adjacent first rotor laminations of the plurality of first rotor laminations, the second rotor lamination having a second pattern distinct from the first pattern, the second pattern including a retention mechanism defined thereon that extends generally into the first rotor slot; inserting the magnet into the rotor slot; and advancing an auxiliary tool toward the first and second rotor laminations, wherein the plurality of second rotor laminations are deflected upon the advancing, the respective retention mechanisms deflecting into the magnet creating a retention load retaining the magnet within the rotor slot. ### Claim 9 (depends on 8) The method of claim 8, wherein the auxiliary tool comprises a first auxiliary tool, wherein the plurality of first rotor laminations do not deflect upon the advancing of the first auxiliary tool into the plurality of second rotor laminations. ### Claim 10 (depends on 9) The method of claim 9, wherein the plurality of first rotor laminations outnumber the plurality of second laminations. ### Claim 11 (depends on 8) The method of claim 8, wherein the second rotor lamination defines an edge at the rotor slot, wherein the retention mechanism deflects causing the retention load of the magnet against the edge. ### Claim 12 (depends on 8) The method of claim 8, wherein the auxiliary tool is configured to be advanced in a direction parallel to the rotor slot and into the respective retention mechanisms. ### Claim 13 (depends on 1) The method of claim 1, wherein a second rotor lamination of the plurality of second rotor laminations is interleaved between multiple first rotor laminations of the plurality of first rotor laminations. ### Claim 14 An electric machine for powering an electric vehicle, the electric machine comprising: a rotor configured to rotate relative to a stator to drive a rotor shaft and at least one drive wheel of the electric vehicle, the rotor defining at least a first rotor slot configured to receive a magnet therein; a plurality of rotor laminations stacked upon each other each having a first pattern, the plurality of rotor laminations each having a retention mechanism defined thereon; and wherein less than all of the plurality of rotor laminations are configured to deflect upon advancement of an auxiliary tool into the plurality of rotor laminations, the respective retention mechanisms deflecting into the magnet creating a retention load retaining the magnet within the rotor slot. ### Claim 15 (depends on 14) The electric machine of claim 14, wherein the auxiliary tool comprises steps configured thereon, wherein the less than all of the plurality of rotor laminations comprises a predetermined amount of laminations that align with the steps and deflect upon the advancement.