Patents by Inventor Dean James Patterson
Dean James Patterson has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Publication number: 20230402885Abstract: Embodiments of the present disclosure are directed to a rotor assembly for use in a radial flux electric motor assembly having core magnets rotatable relative to end magnets such that the torque constant of the rotor assembly varies. The plurality of end magnets is positioned over the core magnets when the rotor assembly is at rest and the rotor assembly has a first torque constant at rest. The plurality of end magnets can rotate relative to the core magnets upon application of torque to the rotor assembly.Type: ApplicationFiled: June 9, 2022Publication date: December 14, 2023Inventors: Mark Thiele, Greg Heins, Dean James Patterson
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Publication number: 20230052600Abstract: A rotor assembly for use in a radial flux electric motor assembly includes a rotor core having a plurality of rotor poles circumferentially spaced about a central axis, wherein the rotor core includes a first end and an opposing second end. The rotor assembly further includes a plurality of core magnets alternately spaced with the plurality of rotor poles. The plurality of rotor poles define a radial aperture between each pair of circumferentially adjacent rotor poles, and each radial aperture is configured to receive at least one core magnet of the plurality of core magnets therein. A plurality of end magnets are coupled to at least one of the first end and the second end, and at least one end plate coupled to the plurality of end magnets.Type: ApplicationFiled: August 16, 2021Publication date: February 16, 2023Inventors: Mark Thiele, Greg Heins, Dean James Patterson
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Patent number: 10770940Abstract: A rotor module for an axial flux electric machine includes a back iron segment configured for attachment to a rotor base and a plurality of permanent magnets attached to the back iron segment. The back iron segment has a length less than a circumference of the rotor base. Each permanent magnet attached to the back iron segment has an opposite magnetic pole orientation from each adjacent permanent magnet attached to the back iron segment. A plurality of rotor modules is coupled to the rotor base to form a rotor for the axial flux electric machine.Type: GrantFiled: January 31, 2017Date of Patent: September 8, 2020Assignee: Regal Beloit Australia Pty Ltd.Inventors: Mark Thiele, Greg Heins, Matthew J. Turner, Dean James Patterson
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Patent number: 10594180Abstract: A rotor for an electric machine includes a circular rotor base having a first surface, a second surface, and a circumferential outer edge extending from the first surface to the second surface, a plurality of magnets disposed proximate the circumferential outer edge of the circular rotor base, and a plurality of flux guides. Each magnet has a first surface and a second surface. The first surface of each magnet is attached to the first surface of the circular rotor base, and the second surface of each magnet defines a first shape. Each flux guide is attached to the second surface of a different magnet and has a first surface attached to the second surface of a first respective magnet and a second surface opposite the first surface. The second surface of each flux guide defines a second shape different than the first shape of the magnets.Type: GrantFiled: January 31, 2017Date of Patent: March 17, 2020Assignee: Regal Beloit America, Inc.Inventors: Greg Heins, Mark Thiele, Dean James Patterson, Matthew J. Turner
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Patent number: 10541591Abstract: A stator for an axial flux machine includes a back iron, a plurality of stator teeth extending from the back iron, and a plurality of tooth tips attached to the stator teeth. The back iron and the stator teeth include a first material. Each stator tooth has a first end proximate the back iron and a second end. Each tooth tip is attached to the second end of a different stator tooth. The tooth tips include a second material different than the first material.Type: GrantFiled: January 31, 2017Date of Patent: January 21, 2020Assignee: REGAL BELOIT AUSTRALIA PTY, LTD.Inventors: Dean James Patterson, Mark Thiele, Greg Heins, Matthew J. Turner
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Patent number: 10447102Abstract: An electric machine comprising a permanent magnet rotor assembly is provided. The electric machine comprises a permanent magnet rotor assembly comprising a plurality of permanent magnets coupled to a rotor disk and a plurality of magnet shims coupled to the plurality of permanent magnets opposite the rotor disk. Each magnet shim of the plurality of magnet shims has a substantially complementary shape as a respective permanent magnet of the plurality of permanent magnets. The electric machine further comprises a stator core comprising a plurality of stator teeth that define a plurality of slots therebetween. At least one of the plurality of magnet shims is configured to direct magnetic flux from at least one of the plurality of permanent magnets to at least one stator tooth of the plurality of stator teeth.Type: GrantFiled: March 15, 2013Date of Patent: October 15, 2019Assignee: Regal Beloit Australia Pty. Ltd.Inventors: Dean James Patterson, Rafal Pawel Rohoza, Steven Peter Camilleri, Matthew Turner, Charles Richard Langford
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Publication number: 20180219434Abstract: A stator for an axial flux machine includes a back iron, a plurality of stator teeth extending from the back iron, and a plurality of tooth tips attached to the stator teeth. The back iron and the stator teeth include a first material. Each stator tooth has a first end proximate the back iron and a second end. Each tooth tip is attached to the second end of a different stator tooth. The tooth tips include a second material different than the first material.Type: ApplicationFiled: January 31, 2017Publication date: August 2, 2018Inventors: Dean James Patterson, Mark Thiele, Greg Heins, Matthew J. Turner
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Publication number: 20180219441Abstract: A rotor module for an axial flux electric machine includes a back iron segment configured for attachment to a rotor base and a plurality of permanent magnets attached to the back iron segment. The back iron segment has a length less than a circumference of the rotor base. Each permanent magnet attached to the back iron segment has an opposite magnetic pole orientation from each adjacent permanent magnet attached to the back iron segment. A plurality of rotor modules is coupled to the rotor base to form a rotor for the axial flux electric machine.Type: ApplicationFiled: January 31, 2017Publication date: August 2, 2018Inventors: Mark Thiele, Greg Heins, Matthew J. Turner, Dean James Patterson
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Publication number: 20180219442Abstract: A rotor for an electric machine includes a circular rotor base having a first surface, a second surface, and a circumferential outer edge extending from the first surface to the second surface, a plurality of magnets disposed proximate the circumferential outer edge of the circular rotor base, and a plurality of flux guides. Each magnet has a first surface and a second surface. The first surface of each magnet is attached to the first surface of the circular rotor base, and the second surface of each magnet defines a first shape. Each flux guide is attached to the second surface of a different magnet and has a first surface attached to the second surface of a first respective magnet and a second surface opposite the first surface. The second surface of each flux guide defines a second shape different than the first shape of the magnets.Type: ApplicationFiled: January 31, 2017Publication date: August 2, 2018Inventors: Greg Heins, Mark Thiele, Dean James Patterson, Matthew J. Turner
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Patent number: 9467015Abstract: A device for positioning a planar array of magnets within a permanent magnet electrical machine of the type having a rotor and stator with an air gap there between. The device includes a body made of non-ferrous material and having a first side which is attachable to the rotor and a second side which, in an assembled machine, faces the air gap. The first side of the body has a plurality of recesses therein for receiving a corresponding plurality of magnets. The recesses are shaped and arranged to separate the magnets from each other and maintain a consistent spacing between them. When the device is attached to the rotor the magnets are held in a fixed position against the rotor. The electrical machine may be a motor or a generator.Type: GrantFiled: November 1, 2013Date of Patent: October 11, 2016Assignee: Regal Beloit Australia Pty Ltd.Inventors: Charles Richard Langford, Steven Peter Camilleri, Dean James Patterson
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Patent number: 9391500Abstract: An electric machine is described. The electric machine includes a rotor comprising a rotor disk and a plurality of permanent magnets magnetically coupled to the rotor disk. The plurality of permanent magnets include a substantially flat profile and are aligned in a substantially planar array. The electric machine also includes a stator comprising a solid stator core and a plurality of coils each wound around a coil insulating member. The stator core includes a plurality of stator teeth extending substantially parallel to an axis of rotation of the rotor.Type: GrantFiled: March 22, 2011Date of Patent: July 12, 2016Assignee: Regal Beloit America, Inc.Inventors: Michael D. Smith, William A. Ziegler, Michael Garrett, Dean James Patterson, Roger C. Becerra, Ludovic Chretien, Darrel Buttram, Steven Peter Camilleri
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Publication number: 20140265700Abstract: An electric machine comprising a permanent magnet rotor assembly is provided. The electric machine comprises a permanent magnet rotor assembly comprising a plurality of permanent magnets coupled to a rotor disk and a plurality of magnet shims coupled to the plurality of permanent magnets opposite the rotor disk. Each magnet shim of the plurality of magnet shims has a substantially complementary shape as a respective permanent magnet of the plurality of permanent magnets. The electric machine further comprises a stator core comprising a plurality of stator teeth that define a plurality of slots therebetween. At least one of the plurality of magnet shims is configured to direct magnetic flux from at least one of the plurality of permanent magnets to at least one stator tooth of the plurality of stator teeth.Type: ApplicationFiled: March 15, 2013Publication date: September 18, 2014Applicant: Regal Beloit Australia PTY LTDInventors: Dean James Patterson, Rafal Pawel Rohoza, Steven Peter Camilleri, Matthew Turner, Charles Richard Langford
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Publication number: 20140062246Abstract: A device for positioning a planar array of magnets within a permanent magnet electrical machine of the type having a rotor and stator with an air gap there between. The device includes a body made of non-ferrous material and having a first side which is attachable to the rotor and a second side which, in an assembled machine, faces the air gap. The first side of the body has a plurality of recesses therein for receiving a corresponding plurality of magnets. The recesses are shaped and arranged to separate the magnets from each other and maintain a consistent spacing between them. When the device is attached to the rotor the magnets are held in a fixed position against the rotor. The electrical machine may be a motor or a generator.Type: ApplicationFiled: November 1, 2013Publication date: March 6, 2014Applicant: IN MOTION TECHNOLOGIES PTY., LTD.Inventors: Charles Richard Langford, Steven Peter Camilleri, Dean James Patterson
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Patent number: 8598761Abstract: A device for positioning a planar array of magnets within a permanent magnet electrical machine of the type having a rotor and stator with an air gap there between. The device includes a body made of non-ferrous material and having a first side which is attachable to the rotor and a second side which, in an assembled machine, faces the air gap. The first side of the body has a plurality of recesses therein for receiving a corresponding plurality of magnets. The recesses are shaped and arranged to separate the magnets from each other and maintain a consistent spacing between them. When the device is attached to the rotor the magnets are held in a fixed position against the rotor. The electrical machine may be a motor or a generator.Type: GrantFiled: April 29, 2008Date of Patent: December 3, 2013Assignee: In Motion Technologies Pty., Ltd.Inventors: Charles Richard Langford, Steven Peter Camilleri, Dean James Patterson
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Publication number: 20130069467Abstract: An electric machine is described. The electric machine includes a rotor comprising a rotor disk and a plurality of permanent magnets magnetically coupled to the rotor disk. The plurality of permanent magnets include a substantially flat profile and are aligned in a substantially planar array. The electric machine also includes a stator comprising a solid stator core and a plurality of coils each wound around a coil insulating member. The stator core includes a plurality of stator teeth extending substantially parallel to an axis of rotation of the rotor.Type: ApplicationFiled: March 22, 2011Publication date: March 21, 2013Applicant: REGAL BELOIT CORPORATIONInventors: Michael D. Smith, William A. Ziegler, Michael Garrett, Dean James Patterson, Roger C. Becerra, Ludovic Chretien, Darrel Buttram, Steven Peter Camilleri
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Publication number: 20130057105Abstract: A method for manufacturing an interior permanent magnet motor is described herein. The method includes providing a plurality of permanent magnets and fabricating a ferromagnetic rotor core configured to accept the permanent magnets therein such that the ferromagnetic material utilized to retain the permanent magnets within the rotor core operates to concentrate and steer the flux from one or more of the permanent magnets to a stator tooth. The method also includes positioning the rotor core with the permanent magnets therein with respect to a wound, open slot stator core.Type: ApplicationFiled: September 2, 2011Publication date: March 7, 2013Inventors: Dean James Patterson, Steven Stretz, William Stadler, Alan W. Yeadon
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Patent number: 8061171Abstract: The present invention provides a method and machine for producing a slotted wound core (50). The machine includes a punch arrangement (16) arranged to punch apertures in a length of material (12a), a mandrel (22) for receiving the punched material, a control means and a mandrel indexing means. The positioning of the punch arrangement (16) and the mandrel (22) is fixed and the mandrel (22) is arranged to be rotated by the mandrel indexing means after each operation of the punch arrangement so that a roll of punched material is formed on the mandrel (22). The mandrel (22) is rotated by an amount (&ggr;) determined by the control means. The control means determines the indexed amount so that selected apertures punched in the length of material align with one another when the material (12a) is rolled onto the mandrel (22) so that the aligned apertures form respective slots (52) of a desired configuration in the core (50).Type: GrantFiled: December 16, 2009Date of Patent: November 22, 2011Assignee: In Motion TechnologiesInventors: Dean James Patterson, Steven Peter Camilleri, Lyell Douglas Embery
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Publication number: 20100164316Abstract: A device for positioning a planar array of magnets within a permanent magnet electrical machine of the type having a rotor and stator with an air gap there between. The device includes a body made of non-ferrous material and having a first side which is attachable to the rotor and a second side which, in an assembled machine, faces the air gap. The first side of the body has a plurality of recesses therein for receiving a corresponding plurality of magnets. The recesses are shaped and arranged to separate the magnets from each other and maintain a consistent spacing between them. When the device is attached to the rotor the magnets are held in a fixed position against the rotor. The electrical machine may be a motor or a generator.Type: ApplicationFiled: April 29, 2008Publication date: July 1, 2010Applicant: IN MOTION TECHNOLOGIES PTY LIMITEDInventors: Charles Richard Langford, Steven Peter Camilleri, Dean James Patterson
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Publication number: 20100139353Abstract: The present invention provides a method and machine for producing a slotted wound core (50). The machine includes a punch arrangement (16) arranged to punch apertures in a length of material (12a), a mandrel (22) for receiving the punched material, a control means and a mandrel indexing means. The positioning of the punch arrangement (16) and the mandrel (22) is fixed and the mandrel (22) is arranged to be rotated by the mandrel indexing means after each operation of the punch arrangement so that a roll of punched material is formed on the mandrel (22). The mandrel (22) is rotated by an amount (&ggr;) determined by the control means. The control means determines the indexed amount so that selected apertures punched in the length of material align with one another when the material (12a) is rolled onto the mandrel (22) so that the aligned apertures form respective slots (52) of a desired configuration in the core (50).Type: ApplicationFiled: December 16, 2009Publication date: June 10, 2010Applicant: IN MOTION TECHNOLOGIES PTY. LTD.Inventors: Dean James Patterson, Steven Peter Camilleri, Lyell Douglas Embery
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Patent number: 7654123Abstract: The present invention provides a method and machine for producing a slotted wound core (50). The machine includes a punch arrangement (16) arranged to punch apertures in a length of material (12a), a mandrel (22) for receiving the punched material, a control means and a mandrel indexing means. The positioning of the punch arrangement (16) and the mandrel (22) is fixed and the mandrel (22) is arranged to be rotated by the mandrel indexing means after each operation of the punch arrangement so that a roll of punched material is formed on the mandrel (22). The mandrel (22) is rotated by an amount (&ggr;) determined by the control means. The control means determines the indexed amount so that selected apertures punched in the length of material align with one another when the material (12a) is rolled onto the mandrel (22) so that the aligned apertures form respective slots (52) of a desired configuration in the core (50).Type: GrantFiled: February 3, 2005Date of Patent: February 2, 2010Assignee: In Motion Technologies Pty. Ltd.Inventors: Dean James Patterson, Steven Peter Camilleri, Lyell Douglas Embery