Delphi Technologies, Inc.

Gm Global Technolgoy Operations, Inc.

David Allen Score

David Earl Gay

Albert Anthony Skinner

Ahmed Mostafa El-Antably

Robert W Ward

Ralph H Johnston

Frank A Wilder

Sam B Parker

A high-density stator core for use in electrodynamic devices is fabricated by the electromagnetic pressing of an iron-based powder coated with a dielectric material and methods for performing the electromagnetic pressing are disclosed. The stator core includes a yoke portion that may further include a plurality of integral poles extending either radially outward from an outer circumferential surface of the yoke portion or radially inward from an interior circumferential surface of the yoke portion. The stator core is formed as a near-net-shape compact by an electromagnetic pressing process and has an as-formed density of at least about 98% of the theoretical density.

Method for fabricating a highly-dense powder iron pressed stator core for use in alternating current generators and electric motors

A reluctance rotor and method for manufacturing reluctance rotors having soft magnetic regions and regions with magnetic properties that are dissimilar to those of the soft magnetic region so as to create a flux barrier. The method generally entails producing a magnetic body having a central axis and an outer peripheral surface. The body is composed of concentric regions, at least one of which is a soft magnetic region while at least a second region of the concentric regions is formed of a material with dissimilar magnetic properties to the soft magnetic region. Once formed, the body is divided along radials thereof to form wedge-shaped members, with each wedge-shaped member having coaxial arcuate regions that are portions of the concentric regions of the body. As a result of the manner in which the body is divided, the wedge-shaped members have radial surfaces defined where the wedge-shaped members were divided from the body, and each wedge-shaped member also has a distal surface corresponding to the outer peripheral surface of the body. The wedge-shaped members are then arranged about an axis of symmetry corresponding to the axis of rotation of the rotor, with the distal surfaces of the wedge-shaped members disposed adjacent the axis of symmetry and facing each other, and with the radial surfaces of the wedge-shaped members facing away from the axis of symmetry. The wedge-shaped members are then bonded together and machined if necessary to form the rotor of the reluctance motor.

Rotor for a reluctance motor

Ceramic-coated powdered ferromagnetic materials for forming magnetic articles, and which maintain the mechanical and magnetic properties of the articles at high temperatures, such as during annealing to relieve stresses induced during the forming operation. The ceramic coatings are formed by one of several techniques to provide an encapsulating layer on each ferromagnetic particle. The particles are then compacted to form a solid magnetic article, which can be annealed without concern for degrading the ceramic coating.

Method of forming high-temperature magnetic articles and articles formed thereby

An ignition coil for a spark ignition engine includes a cylindrical magnetic core having opposite first and second ends. Preferably, the magnetic core has a circular cross section. Permanent magnets similarly shaped as the core are disposed at the ends of the magnetic core. The magnets are made from a microencapsulated magnetic material, resulting in increased resisitivity and decreased eddy current loss. By using the microencapsulated magnets, the voltage output of the ignition coil is increased while requiring no additional input energy. A primary winding is wound about the magnetic core between the first and second ends. A secondary winding assembly is disposed about the primary winding and the core. The secondary winding assembly includes a spool and secondary winding wound thereon. The secondary winding is inductively coupled to the primary winding. An outer case is disposed about said magnetic core, magnets and the primary and secondary windings.

Ignition coil with microencapsulated magnets

Disclosed is a process for producing an AC cylindrical electromagnetic ignition coil core (28) comprising: filling a cylindrical holding container (20) with powdered metal; placing the filled container into an electromagnetic field and compacting, in the radial direction, the powder in the container by subjecting the powder to the electromagnetic field; and recovering the compacted ignition coil core (28).

Electromagnetic compacting of powder metal for ignition core application

A process for pneumatically isostatically compacting a sintered compact to densify the compact wherein the surface of the compact is oxidized to form a gas impervious oxide barrier on said surface before the compact is subjected to the pneumatic isostatic compaction process. Oxidation of the compact surface is preferably accomplished by steaming the compact before or after sintering.

Pneumatic isostatic compaction of sintered compacts

A method of manufacturing an armature for a DC motor comprising the steps of: (a) retaining a plurality of armature conductors pre-positioned in a pre-mold position; (b) placing the armature conductors in a mold; (c) adding to the mold a predetermined quantity of soft-magnetic particles, each soft-magnetic particle coated with a non-magnetic material, wherein said particles surround at least a portion of each of the conductors; (d) applying pressure to the mold to affect a compaction molding of the coated soft magnetic particles into a composite structure, wherein the particles and the non-magnetic material form a composite structure armature core substantially encapsulating the conductors within the armature core.

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Shirley, IN, United States of America

David Allen Score