Ford Global Technolgoies, LLC

Devan James Anderson

Shailesh Shrikant Kozarekar

Joel A Hetrick

Singar Rathnam

Dexiang Dallis Sun

Matthew Schmitt

A rotor assembly for an electric motor includes a rotor core, a plurality of magnets, and a rotor core mold member. The rotor core defines a rotor bore and a plurality of cavities distributed about the rotor bore and extending through the rotor core. The plurality of magnets are disposed in the plurality of cavities. The rotor core mold member extends through the plurality of cavities to retain the plurality of magnets therein and, from the cavities, extends to a first end of the rotor core forming a containment ring at the first end. The containment ring forms a rim above a surface of the first end to restrict flow of a fluid to an outer side surface of the rotor core.

Rotor assembly having a containment ring for an electric motor

A stacked plurality of alternating laminations and adhesive layers of a rotor are arranged such that each of the adhesive layers bonds an outer periphery of an adjacent pair of the laminations together. Each of the laminations includes a plurality of interlocks, disposed about a central region of the lamination radially inside the outer periphery and lacking presence of any of the adhesive layers, that engage a same adjacent one of the laminations.

Hybrid interlock and adhesive rotor cores

A skewed rotor core assembly having a resin mold disposed in a plurality of longitudinal channels and a resin flow path is provided. The rotor core has a first and second magnet stack each defining a plurality of longitudinal channels. The plurality of longitudinal channels for the first stack are misaligned with the plurality of longitudinal channels for the second stack. Methods of making the same are also provided.

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Taylor, MI, United States of America

Devan James Anderson