Abstract: A stator for an electrical motor or generator and method for manufacturing such stator includes providing a plurality of teeth and joining the teeth with a yoke. An electrically conductive winding is applied around each of the teeth. The teeth and/or yoke may be made from a stack of low-loss magnetic material sheets. The teeth and/or yoke may be made by folding a stack of magnetic material sheets.

Abstract: A stator for an electrical motor or generator and method for manufacturing such stator includes providing a plurality of teeth and joining the teeth with a yoke. An electrically conductive winding is applied around each of the teeth. The teeth and/or yoke may be made from a stack of low-loss magnetic material sheets. The teeth and/or yoke may be made by folding a stack of magnetic material sheets.

Abstract: A composite rotor for an axial airgap, permanent magnet dynamoelectric machine comprises a plurality of magnet subassemblies adhesively bonded together to form the rotor. Each magnet subassembly comprises a rotor permanent magnet and an optional spacer. A fibrous belt is wrapped around the periphery of each subassembly to provide high tensile strength at least along the radial sides of the subassembly. The belt is preferably infiltrated with an adhesive agent, such as an epoxy resin, that is used to bond the subassemblies. The rotor is thereby provided with high strength and low mass, making it suitable for use in a high-speed, high pole count electric machine.

Abstract: An electromagnetic component is formed from a pre-form comprising layers of soft magnetic metal ribbon. Adhesive is applied to permeate the pre-form and is then cured. The bonded pre-form is placed within a milling assembly that supports and constrains the ribbon layers during a milling operation used to process the pre-form into an electromagnetic component shape. Optionally, the shape is thermally processed. The resulting electromechanical component has attractive soft magnetic properties, including low core loss, that render it useful as a component in electric motors and generators and static inductive devices operable at high excitation frequencies.

Abstract: A composite rotor for an axial airgap, permanent magnet dynamoelectric machine comprises a plurality of magnet subassemblies adhesively bonded together to form the rotor. Each magnet subassembly comprises a rotor permanent magnet and an optional spacer. A fibrous belt is wrapped around the periphery of each subassembly to provide high tensile strength at least along the radial sides of the subassembly. The belt is preferably infiltrated with an adhesive agent, such as an epoxy resin, that is used to bond the subassemblies. The rotor is thereby provided with high strength and low mass, making it suitable for use in a high-speed, high pole count electric machine.

Abstract: A dynamoelectric, rotating electric machine includes a stator assembly that includes stacked stator coil windings. The machine is preferably a polyphase, axial airgap device. Improved slot filling results from the stacked stator coil configuration. Device performance capability is thereby increased. The stator assembly of the electric device has a magnetic core made from low loss, high frequency material. A high pole count permits the electrical device to operate at high commutating frequencies, with high efficiency, high power density and improved performance characteristics. Low-loss materials incorporated by the device include amorphous metals, nanocrystalline metals, optimized Si—Fe alloys, grain-oriented Fe-based materials or non-grain-oriented Fe-based materials.

Abstract: A radial gap, transverse flux dynamoelectric machine comprises stator and rotor assemblies. The rotor assembly comprises at least two axially spaced, planar rotor layers having equal numbers of magnetic poles of alternating polarity disposed equiangularly about the rotor peripheral circumference. A magnetically permeable member optionally links adjacent rotor magnets. The stator assembly comprises a plurality of amorphous metal stator cores terminating in first and second polefaces. The cores are disposed equiangularly about the peripheral circumference of the stator assembly with their polefaces axially aligned. Respective first and second polefaces are in layers radially adjacent corresponding rotor layers. Stator windings encircle the stator cores. The device is operable at a high commutating frequency and may have a high pole count, providing high efficiency, torque, and power density, along with flexibility of design, ease of manufacture, and efficient use of magnetic materials.

Abstract: A high intensity lighting system comprises a plurality of high intensity discharge lamps electrically connected to a polyphase alternator and a prime mover mechanically connected to the alternator. An inherent impedance characteristic of the alternator permits the lamps to be reliably started and energized without any separate ballast or comparable impedance element. The alternator comprises a stator having teeth extending from a backiron. The teeth consist of the alternator phases, and the coils encircle the respective teeth of each pair and are wound in opposite sense and connected in series. The machine is preferably an axial airgap device wherein the stator assembly has a magnetic core made from low loss, high frequency material. A high pole count permits the electrical device to operate at high commutating frequencies, with high efficiency, high power density and improved performance characteristics.

Abstract: The invention relates generally to an electric device, such as an electric motor, a generator, or a regenerative motor, having a wound stator core made from advanced low-loss material. In preferred embodiments, the electric device is an axial airgap-type configuration. The invention provides an electric device having a high pole count that operates at high commutating frequencies, with high efficiency and high torque and power densities. Advanced low-loss materials exploited by the present invention include amorphous metals, nanocrystalline metals, and optimized Fe-based alloys.

Abstract: A dynamoelectric, rotating electric machine includes a stator assembly that includes stacked stator coil windings. The machine is preferably a polyphase, axial airgap device. Improved slot filling results from the stacked stator coil configuration. Device performance capability is thereby increased. The stator assembly of the electric device has a magnetic core made from low loss, high frequency material. A high pole count permits the electrical device to operate at high commutating frequencies, with high efficiency, high power density and improved performance characteristics. Low-loss materials incorporated by the device include amorphous metals, nanocrystalline metals, optimized Si—Fe alloys, grain-oriented Fe-based materials or non-grain-oriented Fe-based materials.

Abstract: A high intensity lighting system comprises a plurality of high intensity discharge lamps electrically connected to a polyphase alternator and a prime mover mechanically connected to the alternator. An inherent impedance characteristic of the alternator permits the lamps to be reliably started and energized without any separate ballast or comparable impedance element. The alternator comprises a stator having teeth extending from a backiron. The teeth consist of the alternator phases, and the coils encircle the respective teeth of each pair and are wound in opposite sense and connected in series. The machine is preferably an axial airgap device wherein the stator assembly has a magnetic core made from low loss, high frequency material. A high pole count permits the electrical device to operate at high commutating frequencies, with high efficiency, high power density and improved performance characteristics.

Abstract: A rotating, dynamoelectric machine, such as an electric motor, a generator, or a regenerative motor, comprises a stator assembly that includes a backiron section, a plurality of stator tooth sections, and a frontiron. The dynamoelectric machine has an axial airgap-type configuration. In addition, the electric machine has a high pole count that operates at high commutating frequencies, with high efficiency, high power density and reduced heating in the rotor. Low-loss materials employed in the dynamoelectric machine include amorphous metals, nanocrystalline metals, optimized Fe-based alloys, and optimized grain-oriented Fe-based materials or non-grain-oriented Fe-based materials.

Abstract: The invention relates generally to an electric device, such as an electric motor, a generator, or a regenerative motor, having a wound stator core made from advanced low-loss material. In preferred embodiments, the electric device is an axial airgap-type configuration. The invention provides an electric device having a high pole count that operates at high commutating frequencies, with high efficiency and high power density. Advanced low-loss materials exploited by the present invention include amorphous metals, nanocrystalline metals, and optimized Si—Fe alloys.

Abstract: An axial gap dynamoelectric machine comprises first and second stators disposed coaxially with an intermediate rotor. The stators are selectively aligned with an axial offset between the positions of their respective teeth and slots. The stators comprise toroidal cores having laminated layers composed of a material selected from the group consisting of amorphous and nanocrystalline metals and optimized Fe-based alloy. Optionally, the machine further comprises misalignment means for adjusting the offset of the stators. Adaptive adjustment permits the machine to be operated to in a mode that reduces the back EMF of the motor, allowing constant voltage to be maintained as speed is increased. Reducing back EMF also allows a wider range of operating speed, especially in combination with use of high pole counts. Alternatively, the machine can be operated, e.g. at lower speed, in a constant torque mode. The machine may exploit the high pole count achievable by use of improved soft magnetic materials.

Abstract: A radial gap, transverse flux dynamoelectric machine comprises stator and rotor assemblies. The rotor assembly comprises at least two axially spaced, planar rotor layers having equal numbers of discrete rotor magnets disposed equiangularly about the rotor peripheral circumference with alternating north and south poles. A magnetically permeable member optionally links adjacent rotor magnets. The stator assembly comprises a plurality of amorphous metal stator cores terminating in first and second polefaces. The cores are disposed equiangularly about the peripheral circumference of the stator assembly with their polefaces axially aligned. Respective first and second polefaces are in layers radially adjacent corresponding rotor layers. Stator windings encircle the stator cores. The device is operable at a high commutating frequency and may have a high pole count, providing high efficiency, torque, and power density, along with flexibility of design, ease of manufacture, and efficient use of magnetic materials.

Abstract: A radial gap, transverse flux dynamoelectric machine comprises stator and rotor assemblies. The rotor assembly comprises at least two axially spaced, planar rotor layers having equal numbers of magnetic poles of alternating polarity disposed equiangularly about the rotor peripheral circumference. A magnetically permeable member optionally links adjacent rotor magnets. The stator assembly comprises a plurality of amorphous metal stator cores terminating in first and second polefaces. The cores are disposed equiangularly about the peripheral circumference of the stator assembly with their polefaces axially aligned. Respective first and second polefaces are in layers radially adjacent corresponding rotor layers. Stator windings encircle the stator cores. The device is operable at a high commutating frequency and may have a high pole count, providing high efficiency, torque, and power density, along with flexibility of design, ease of manufacture, and efficient use of magnetic materials.

Abstract: The invention relates generally to an electric device, such as an electric motor, a generator, or a regenerative motor, having a wound stator core made from advanced low-loss material. In preferred embodiments, the electric device is an axial airgap-type configuration. The invention provides an electric device having a high pole count that operates at high commutating frequencies, with high efficiency and high power density. Advanced low-loss materials exploited by the present invention include amorphous metals, nanocrystalline metals, and optimized Si—Fe alloys.