Gm Global Technolgoy Operations, Inc.

Delco Electronics Corporation

Robert W Ward

Thaddeus Schroeder

Bruno P Lequesne

David E Gay

William E Boys

Sam B Parker

Ahmed Mostafa El-Antably

Chi Hung Leung

David Allen Score

Melvin H Hallmann

Yuchi P Peng

Robert E Campbell

George A Shinkle

Donald E Lake

John S Zgunda

Rodney G Hunter

Robert A Jablonski

Daniel I Feaster

A soft magnetic structure substantially comprised of a plurality of magnetic field carrying particles molded and retained in a predetermined shape, bonded in that shape by an insulating binding agent, wherein said particles have grain alignment substantially parallel to a preferred direction, and wherein said preferred direction is parallel to a direct axis providing the structure with a high direct axis to quadrature axis reactance ratio.

Grain oriented composite soft magnetic structure

A mass of ferromagnetic particles moldable into stable, high strength, magnetic cores useful in thermally and chemically hostile environments comprising an iron core and a continuous layer of polyetherimide, polyethersulfone or polyamideimide spray coated onto the surface of each particle. A method of preheating and molding the particles is disclosed.

Composite iron material

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.

Composite armature assembly

A rotor for an alternating current generator of the Lundell type. The rotor shaft carries two segments which have interleaved pole teeth. The rotor has a core member and a field coil disposed about the core member. The segments and/or core member are formed of compressed powder iron particles having a particle size in a range of about 10 to 250 microns. In the manufacture of the core and/or segments the iron powder particles are coated with a thermoplastic material and this thermoplastic coated iron particle material is compacted in the molding dies of a press. After compaction to the desired shape, the part is sintered at a temperature of about 2050.degree. F. to burn-off the thermoplastic material that coated the iron particles.

Alternating current generator rotor

A semiconductor magnetoresistive sensor and a method for its assembly is specifically provided. The preferred assembly method of this invention is compatible with automated semiconductor chip placement and packaging technology, so as to alleviate the previous requirement that the semiconductor sensing element be separately packaged. The sensor leads are substantially embedded within a powdered metal permanent magnet body. An exposed terminal end of each lead is available for electrical and adhesive contact to a subsequently attached magnetoresistive semiconductor sensing element, using conventional semiconductor placement and packaging techniques. The powdered metal magnetic body is preferably formed by utilizing powder metal compaction techniques, wherein the powder metal is compacted around the interior electrical leads. The teachings of this invention may also be employed to form a variety of electrical sensors and devices, wherein the leads are substantially embedded within a metal core so as to produce a solid assembly. The embedded leads may have a variety of shapes, such as straight or coiled, may range in number from one to a plurality, and may have a variety of physical properties, such as magnetic or non-magnetic, depending on the desired application.

Sensor assembly having embedded wires within a powder metal core and a

A polymeric coating material is provided for coating powdered materials and, more particularly, for coating powdered metals formed into parts and sintered, such as to form magnetic cores. The thermoplastic material is polyphenylene oxide which, when properly applied to metal particles to form a magnetic core, is characterized by being sufficiently volatile so as to prevent the formation of contaminants or voids within the sintered article which would be detrimental to the physical properties of the sintered article. Moreover, polyphenylene oxide provides sufficient lubrication and adhesion between adjacent metal particles during an initial compaction process so as to sustain the desired shape of the molded article and maximize metal particle density without the use of additional lubricants, thereby preventing the formation of additional contaminants and/or voids within the resultant sintered article from these lubricants.

Method of sintering using polyphenylene oxide coated powdered metal

A method of manufacturing an electromagnetic device having regions of ferromagnetic material and permanent magnet material is disclosed. The electromagnetic assemblies of this invention utilize thermoplastic encapsulated iron powders and epoxy resin encapsulated permanent magnet powder. A motor frame and permanent magnet assembly is formed in a first example, while a permanent rotor assembly is formed in a second. The motor frame and permanent magnet assembly has a ferromagnetic frame defined by a region of encapsulated iron powder and an annular array of permanent magnets defined by a region of encapsulated permanent magnet material. The permanent magnet rotor assembly has a ferromagnetic core defined by a region of encapsulated iron powder and a permanent magnet shell defined by a region of encapsulated permanent magnet material. In the processing of both the motor frame and permanent magnet assembly and the rotor assembly, annular inner and outer punch elements coaxial with a central core rod are supported within a heated die casing for independent extension and retraction along the central axis. The inner and outer punch elements are retracted to form cavities which are filled with the encapsulated permanent magnet and ferrous powders, respectively, for the motor frame and permanent magnet assembly, while the reverse exists for the manufacture of the permanent magnet rotor assembly. Coaxial pressing mechanisms individually and concurrently compress the powders to fuse and compact them to a predetermined axial length.

Method for manufacturing a dynamoelectric device

A package for a magnetic field sensitive element, such as a magnetoresistor, includes at least two planar layers of a relatively stiff ferromagnetic material which is also electrically conductive. The layers have opposed edges which are in closely spaced relation to form a narrow gap therebetween. A terminal tab is integral with and extends from each layer. A magnetic field sensitive element is on a surface of at least one of the layers and preferably extends across the gap to be on both layers. The magnetic field sensitive element has a pair of contacts each of which is electrically connected to a separate one of the layers. A permanent magnet is mounted on and insulated from the surface of the layers opposite the magnetic field sensitive element. A protective layer of an insulating material may cover the magnetic field sensitive element and the layers with the terminal tabs extending therefrom.

Package for the magnetic field sensitive device

Method for embedding wires within a powder metal core and sensor

A frame and permanent magnet assembly for a dynamoelectric machine where the frame carries a plurality of permanent magnets. The frame is formed of iron powder particles that are bound together by a thermoplastic material. In the manufacture of the assembly, iron powder particles that are coated with a thermoplastic material are molded to the permanent magnets. The permanent magnets have surfaces that are interlocked to the material of the frame thereby eliminating the need for mechanical fasteners or an adhesive to secure the permanent magnets to a frame.

Frame and magnet assembly for a dynamoelectric machine

A wiring harness clip comprises an elongated body having a channel intermediate end portions which are attached to a wiring harness by a wrapping or tape. A slide which is slideably mounted in the channel so that a self-expanding head of the slide which is insertable into a hole in a panel for attaching the wiring harness clip to the panel adjusts to the location of the hole.

Adjustable wiring harness clip

A dual-face, internally-mounted cooling fan is provided in a dynamoelectric machine, e.g. an alternating current generator. The generator includes a ventilated housing supporting a stator assembly and a rotor assembly. The fan includes a divider disk having a plurality of blades provided on each surface and is mounted to rotate with the rotor assembly. As the fan is rotated, a plurality of separate air currents are drawn axially into the housing for cooling. The divider disk prohibits substantial mixing of currents drawn from opposite ends before they are radially expelled from the housing.

Growing community of inventors

Anderson, IN, United States of America

Robert W Ward