Tesla Motors, Inc.

Rudy Garriga

Erik James Shahoian

David Frederick Lyons

Jeffrey Brian Straubel

A method of making a rotor assembly for an electric motor by adding bars made out of a conducting material such as copper, to spaces between the teeth of a stack of discs, inserting bars referred to as 'slugs', also made out of a conducting material such as copper, in the spaces between the bars on either side of the stack of discs, radially compressing the bars and discs, one or both of which are plated or otherwise coated with a braising material, and then heating the rotor to allow the bars to be braised to the slugs.

Method for making an efficient rotor for an electric motor

A rotor assembly and a method for fabricating the same are provided in which a solid rotor ring is formed at either end of a stack of laminated discs, the solid rotor rings yielding improved electrical and mechanical characteristics in a low weight assembly. The solid rotor rings are fabricated by brazing slugs between the end portions of the rotor bars, the braze joints contacting a large percentage (at least 90 %) of the rotor bar end portions.

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Los Altos, CA, United States of America

Rudy Garriga