Energy-efficient ferromagnetic stator and core apparatus
OwnerBradner L. Hiseyinventor
Life of this patent
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Abstract
Energy efficiency of electric motors and transformer, inductor and ballast apparatus is increased through use of amorphous ferromagnetic materials and thin section electrical steels by methods using folding of lamination stock, forming of lamination stock after folding or punching, and stacking to form substantially solid flux-conducting structures. Such apparatus may employ multiple ferromagnetic materials to conduct major portions of the magnetic flux in the apparatus magnetic circuit. Apparatus is also described in which magnetic and mechanical support functions reside in differing ferromagnetic or structural plastic materials in composite structures.
Claims23
In a structure for forming a magnetic flux path in an electrical apparatus, a plurality of superposed elongate ferromagnetic strips having first and second edges and longitudinal axes, said strips having superposed fanfolds therein extending entirely across said strips from the first edge to the second edge at angles with respect to the longitudinal axes of said strips, said strips having therein fold angles less than 180 degrees, said strips being disposed closely adjacent to each other with a plurality of immediately adjacent folds in registration to form a substantially solid laminated structure to provide the flux path.
In a radial-gap electric motor having a longitudinal axis and having a stator structure, an elongate ferromagnetic strip having first and second edges and a longitudinal axis, said strip having fanfolds therein extending entirely across said strip from the first edge to the second edge at angles with erspect to the longitudinal axes of said strip, said strip having therein fold angles less than 180 degrees, said strip having faces between said fanfolds, said strips being deflected about the longitudinal axis of the motor, said strip having greater fold angles at the inner margin of the geometric figure than at the outer margin to provide a twist in each face, said strip having superposed portions extending over more than one turn disposed closely adjacent to each other along the longitudinal axis of the motor with a plurality of immediately adjacent folds in registration to form a substantially solid laminated magnetic flux path in the stator.
A structure as in claim 26 together with a motor frame, a plurality of stator tooth assemblies, a plurality of fanfolded magnetic circuit rings disposed around the stator tooth assemblies and a plurality of stator support rings bonded to said stator tooth assemblies and secured to said motor frame.
In an axial-gap motor construction having a longitudinal axis, a stator structure comrpising a toroid flat-wound of ferromagnetic strip stock having first and second surfaces, with the first and second surfaces of the flat-wound strip being disposed generally parallel to the longitudinal axis of the motor, said toroid having an end, a ferromagnetic powder stator slot and tooth assembly molded separately, and adhesive means bonding said toroid end to said ferromagnetic powder stator slot and tooth assembly.
In a magnetic core structure for an alternating-current apparatus, a plurality of superposed ferromagnetic strips each having first and second surfaces and first and second edges and a longitudinal axis, said first and second surfaces lying nominally in a plane, each of said strips having a turn in the longitudinal axis thereof lying nominally in said plane, each turn having fanfolds therien extending entirely across the strip from the first edge to the second edge and each turn having radially inner and radially outer margins, said fanfolds in said turns having greater fold angles at the radially inner margin of the turn than at the radially outer margin, said fanfolds effecting said turn while maintaining said first and second surfaces of the unfolded portions of the strip nominally in said plane.
In a magnetic core structure for an alternating-current apparatus, a plurality of superposed ferromagnetic strips each having first and second surfaces and first and second edges and a longitudinal axis, said first and second surfaces lying nominally in a plane, each of said strips having a turn in the longitudinal axis thereof lying nominally in said plane, each strip being folded entirely across the strip from the first edge to the second edge at an angle to the longitudinal axis of each strip and having the folds compressed so that the surfaces of the strip adjacent to a fold are in close proximity to each other, said fold effecting said turn while maintaining said first and second surfaces nominally in said plane.
In a radial gap motor construction, a motor frame, a stator, said stator comprising a stator tooth assembly, a fanfolded stator magnetic circuit ring surrounding said stator tooth assembly, stator support rings bonded to the stator tooth assembly and secured in the motor frame for supporting said stator tooth assembly in said frame, said stator magnetic circuit rings being helically formed from multiple interleaved strips of fanfolded ferromagnetic strip stock and a rotor rotatably mounted in the stator for rotation about a longitudinal axis.
In a radial gap motor construction, a motor frame, a stator, said stator comprising a stator tooth assembly, stator support rings secured to the motor frame and bonded to the stator tooth assembly for supporting the stator tooth assembly in the motor frame, a fanfolded stator magnetic circuit ring surrounding said stator tooth assembly and a helically wound stator compression ring interposed between the stator magnetic circuit ring and the stator tooth assembly and a rotor rotatably mounted in the stator for rotation about a longitudinal axis.
Dependencies are inferred from the claim text.