D.C. PM motor and generator with a stator core assembly formed of pressure shaped processed ferromagnetic particles

An electricity generator exhibiting an air gap radius extending from a generator axis and drivably operable to generate a maximum current, comprising:

• a bearing support assembly;
• a bearing mounted for rotation about said generator axis upon said bearing support assembly;
• a rotor having a sequence of generally arcuate regions of predetermined magnetization and confronting surface of first principal dimension in parallel with said generator axis, mounted for rotation with said bearing, said confronting magnetic surface being located in correspondence with said air gap radius;
• a stator core assembly having a select number of spaced core components each being disposed about a radius extending from said generator axis, formed of pressure shaped processed ferromagnetic particles which are generally mutually insulatively associated, each said core component having an induction region of second principal dimension in parallel with said generator axis having a value close in value to the value of said first principal dimension, said induction region extending to an arcuate flux interaction surface located adjacent said rotor confronting magnetic surface to define an air gap and having a face length parallel with said generator axis and an arcuate face width generally normal to said radius, said face length exhibiting said second principal dimension selected to provide a coupling induction of the magnetic flux derived from said rotor regions of predetermined magnetization, each said core component having a winding support region extending in flux transfer communication from said induction region having a third principal dimension parallel with said generator axis, and a winding region width generally normal to said radius, and said stator assembly including a back iron assembly formed of pressure shaped processed ferromagnetic particles which are generally mutually insulatively associated, said back iron assembly being in flux transfer association with each said core component adjacent said winding support region;
• a field winding assembly configured with multiple field turns, said field turns being located at each said core component and extending in electromagnetic flux coupling relationship about said winding support region, said field turns being coupled with a generator output for providing generated current upon driven rotation of said rotor upon said bearing;
• and
• each said core component induction region and winding support region, and said back iron assembly having cross sectional area attributes effective for conveyance of magnetic flux derived from said regions of predetermined magnetization and from said field winding assembly without saturation at said maximum current.

The method of forming a stator and field winding assembly for an electromotive device having a rotor supporting a multiple pole permanent magnet assembly drivably rotatable about a motor axis, comprising the steps of:

• (a) providing a predetermined number of core components, each being formed of pressure shaped processed ferromagnetic particles which are generally mutually insulatively associated, each said core component having an induction region extending along a radius from said axis to an arcuate flux interaction surface, said induction region extending to and being integrally formed with a winding support region of predetermined winding region width, said winding support region extending to and being integrally formed with a back iron extension region having two, spaced apart core component back iron abutting surfaces;
• (b) providing a predetermined number of discrete back iron linking members each having two, spaced apart linking abutting surfaces and each being formed of pressure shaped processed ferromagnetic particles;
• (c) positioning a core component winding over said winding support region;
• and
• (d) then attaching said back iron linking members to said core components in a manner wherein said back iron abutting surfaces are in intimate abutting contact with said linking abutting surfaces.

An electricity generator, comprising:

• a rotor rotatable about a generator axis having a sequence of generally arcuate regions of predetermined magnetization and confronting magnetic surface of first principal dimension in parallel with said generator axis;
• a stator core assembly having spaced core components formed of pressure shaped processed ferromagnetic particles which are generally mutually insulatively associated, each said core component having an induction region of second principal dimension in parallel with said generator axis between first and second induction region surfaces and extending to an arcuate flux interaction surface located adjacent said rotor confronting magnetic surface to define an air gap and having a face length parallel with said generator axis of value about equal to said first principal dimension, said induction region extending to an integrally formed winding support region having oppositely disposed first and second support region surfaces spaced apart a third principal dimension less than said second principal dimension, a first forward coupling transition extending a first forward level-defining distance between said first winding support region surface and said first induction region surface, and including a back iron assembly formed of pressure shaped processed ferromagnetic particles which are generally mutually insulatively associated, said back iron assembly being in flux transfer association with each said core component adjacent said winding support region and having a fourth principal dimension parallel with said generator axis extending between first and second spaced apart back iron surfaces;
• and
• a field winding assembly including winding components located at each said core component and extending in electromagnetic flux coupling relationship about said winding support region, said winding components being coupled with a generator output for providing generated current upon driven rotation of said rotor about said generator axis.