Patents by Inventor Christopher W. Gabrys

Christopher W. Gabrys 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).

  • Publication number: 20210006116
    Abstract: An electric machine for converting between electrical and rotary mechanical energy includes a rotor journaled to rotate about an axis of rotation, and a stationary stator mounted adjacent to the rotor. The stator has a ferromagnetic backiron with a surface facing the rotor across a magnetic airgap and having windings applied in a winding pattern formed directly onto the stator backiron and adhered to its surface with a pre-applied tacky adhesive. The windings magnetically exert torque upon the rotor across the magnetic armature airgap in response to electric power applied to the windings. The rotor has permanent magnets that generate magnetic flux across the airgap and through the windings. The windings are comprised of pre-bundled multiple individually insulated conductor strands that are electrically connected in parallel but are electrically insulated from each other along their lengths inside said magnetic armature airgap.
    Type: Application
    Filed: August 10, 2020
    Publication date: January 7, 2021
    Applicant: Revolution Electric Motor Company, Inc.
    Inventors: Christopher W. Gabrys, Timothy S. Rogers
  • Publication number: 20200358380
    Abstract: An electronically commutated electric motor includes a rotor, a stator and an electronic drive. The rotor is journaled to rotate about an axis of rotation, the stator is stationary relative to the rotor, and the electronic drive provides synchronous power to the stator and drives the rotor. The rotor has two ferromagnetic radially spaced apart co-rotating rotor portions having a circumferential array of alternating polarity permanent magnet poles that drive magnetic flux back and forth across an armature air gap between said spaced apart rotor portions, and circumferentially through each of said rotor portions. The stator includes an air core armature supported in the armature airgap, and has a non-ferromagnetic structure where located in the magnetic flux in the armature air gap. Three phase windings wound on the armature magnetically exert torque upon the rotor when the windings are electrically energized by the electronic drive.
    Type: Application
    Filed: May 9, 2019
    Publication date: November 12, 2020
    Inventors: Christopher W. Gabrys, Timothy S. Rodgers
  • Publication number: 20200313526
    Abstract: A process for assembly of a brushless air core motor-generator includes assembling a rotor formed from two spaced apart rotor portions having magnetic poles that drive magnetic flux circumferentially through the rotor portions and back and forth across an armature airgap between the rotor portions. An air core armature is made by coating a nonmagnetic armature form with a tacky adhesive layer, and winding armature windings in a winding pattern onto the form with a winding head, using wire comprised of bundled multiple individually insulated conductor strands that are electrically connected in parallel but are electrically insulated from each other along their lengths where located inside the magnetic flux in the armature airgap.
    Type: Application
    Filed: March 28, 2019
    Publication date: October 1, 2020
    Inventors: Christopher W. Gabrys, Timothy S. Rodgers
  • Patent number: 10749419
    Abstract: A process for assembling a brushless motor-generator includes assembling a rotor formed from two spaced apart rotor portions having magnetic poles that drive magnetic flux circumferentially through the rotor portions and back and forth across an armature airgap formed between the rotor portions. An air core armature is formed by coating a substantially nonmagnetic armature form with a tacky adhesive layer, and winding armature windings into a winding pattern onto the substantially nonmagnetic form using wire made of multiple individually insulated conductor strands that are electrically connected in parallel but are electrically insulated from each other along their length when located inside the armature airgap, wherein the strands of said wire are diametrically held together by an outer serve. The winding of the armature form includes sequentially applying pressure to sections of said wire against the tacky adhesive layer.
    Type: Grant
    Filed: September 28, 2017
    Date of Patent: August 18, 2020
    Assignee: Revolution Electric Motor Company, Inc.
    Inventors: Christopher W. Gabrys, Timothy S. Rodgers
  • Patent number: 10683135
    Abstract: A corrugated skid includes top and bottom blanks that are folded and assembled together to produce a double thickness deck supported by double thickness ribs that are folded downward from deck portions of each blank. The ribs of the top blank are split into three sections by two fork passages. The three sections penetrate through slots in the deck portion formed by the bottom blank. The double thickness ribs of the top and bottom blanks intersect with notches at a location below the deck. The double thickness ribs of the top and bottom blanks intersect each other near the center of the corrugated skid to form a continuous four-sided rib support rectangle that resists shifting between the top and bottom blanks.
    Type: Grant
    Filed: December 29, 2017
    Date of Patent: June 16, 2020
    Inventor: Christopher W. Gabrys
  • Patent number: 10486853
    Abstract: A method for assembling a corrugated skid includes selecting first and second planar corrugated blanks and folding the first blank to produce a first double thickness rib that extends out of the plane of the first blank. That blank is placed on a horizontal surface having blades protruding upwards such that the blades penetrate the middle of the double thickness rib and hold it perpendicular to the horizontal surface. The second blank is folded to produce a second double thickness rib that extends out of the plane of the second blank. The second blank is placed on top of the first blank such that the first rib penetrates a slot in the second blank, and the first and second blanks are engaged with one side of each blank facing each other forming a double thickness skid deck with ribs forming depending legs for supporting the skid deck above a supporting surface.
    Type: Grant
    Filed: March 16, 2017
    Date of Patent: November 26, 2019
    Inventors: E. Neil Schopke, Joseph J. Danko, Christopher W. Gabrys
  • Publication number: 20190185207
    Abstract: A corrugated skid includes top and bottom blanks that are folded and assembled together to produce a double thickness deck supported by double thickness ribs that are folded downward from deck portions of each blank. The ribs of the top blank are split into three sections by two fork passages. The three sections penetrate through slots in the deck portion formed by the bottom blank. The double thickness ribs of the top and bottom blanks intersect with notches at a location below the deck. The double thickness ribs of the top and bottom blanks intersect each other near the center of the corrugated skid to form a continuous four-sided rib support rectangle that resists shifting between the top and bottom blanks.
    Type: Application
    Filed: December 29, 2017
    Publication date: June 20, 2019
    Inventor: Christopher W. Gabrys
  • Publication number: 20190058379
    Abstract: A process for assembling a brushless motor-generator includes assembling a rotor formed from two spaced apart rotor portions having magnetic poles that drive magnetic flux circumferentially through the rotor portions and back and forth across an armature airgap formed between the rotor portions. An air core armature is formed by coating a substantially nonmagnetic armature form with a tacky adhesive layer, and winding armature windings into a winding pattern onto the substantially nonmagnetic form using wire made of multiple individually insulated conductor strands that are electrically connected in parallel but are electrically insulated from each other along their length when located inside the armature airgap, wherein the strands of said wire are diametrically held together by an outer serve. The winding of the armature form includes sequentially applying pressure to sections of said wire against the tacky adhesive layer.
    Type: Application
    Filed: September 28, 2017
    Publication date: February 21, 2019
    Applicant: Revolution Electric Motor Company, Inc.
    Inventors: Christopher W. Gabrys, Timothy S. Rodgers
  • Patent number: 9796503
    Abstract: A skid for moving and shipping goods in bulk includes top and bottom die-cut blanks of corrugated material that are each folded along score lines to produce two or more double-thickness ribs. Notches cut across the crest of the ribs in the top blank, and slots cut in the bottom blank on both sides of, and part way into the ribs enable the ribs of the top blank to be inserted through the slots in the bottom blank so the top and bottom blanks are brought together face-to-face producing a double thickness deck. The notches and slots of the top and bottom blank ribs are interlocked to lock the ribs in folded, closed position. The ribs protrude from the double-thickness deck of the skid and contact the floor to support the skid deck and its load of goods above the floor for easy access by forked moving equipment.
    Type: Grant
    Filed: July 11, 2016
    Date of Patent: October 24, 2017
    Inventor: Christopher W. Gabrys
  • Patent number: 9630742
    Abstract: A corrugated paperboard pallet is produced from two flat blanks which comprise a pallet top and a pallet bottom. The two blanks are each folded to produce only two parallel vertically extending double thickness ribs, three horizontal panels, two vertical side walls and two horizontal flaps. The ribs of the pallet top and pallet bottom lock each other from opening in the center of the pallet by intersecting perpendicularly with notches in the ribs. The horizontal flaps lock the ribs from opening at the edges of the pallet by intersecting perpendicularly with notches, and the vertical sidewalls include vertical flaps that open inward defining fork passages whereby the vertical flaps lock said horizontal flaps from opening.
    Type: Grant
    Filed: May 20, 2013
    Date of Patent: April 25, 2017
    Assignee: Lifdek Corporation
    Inventors: Douglas A. Olvey, James L. Sketo, Sean G. Gumbert, Joseph J. Danko, Christopher W. Gabrys
  • Patent number: 9580205
    Abstract: A shipping method includes the steps of receiving stacks of flat die cut corrugated paperboard blanks from a corrugator or sheet plant; loading the stacks of blanks into a pallet assembly machine; folding the blanks together in the assembly machine to produce a corrugated paperboard pallet; and providing the pallets for shipping items to a receiver. The assembly machine folds the blanks using intermittent motion of the blanks through multiple folding sections in the assembly machine. The sections operate by positioning, clamping and folding the blanks using levers that are supported by rotary bearings and driven by pinned end mounted pneumatic cylinders. The assembly machine overcomes misalignment and shifting of the stacks of blanks by picking up single blanks from the top of the stacks using vacuum, and adjusting alignment of the blanks after being picked up but prior to being fed into the first folding section of the assembly machine.
    Type: Grant
    Filed: June 10, 2013
    Date of Patent: February 28, 2017
    Assignee: Lifdek Corporation
    Inventor: Christopher W. Gabrys
  • Publication number: 20170015463
    Abstract: A skid for moving and shipping goods in bulk includes top and bottom die-cut blanks of corrugated material that are each folded along score lines to produce two or more double-thickness ribs. Notches cut across the crest of the ribs in the top blank, and slots cut in the bottom blank on both sides of, and part way into the ribs enable the ribs of the top blank to be inserted through the slots in the bottom blank so the top and bottom blanks are brought together face-to-face producing a double thickness deck. The notches and slots of the top and bottom blank ribs are interlocked to lock the ribs in folded, closed position. The ribs protrude from the double-thickness deck of the skid and contact the floor to support the skid deck and its load of goods above the floor for easy access by forked moving equipment.
    Type: Application
    Filed: July 11, 2016
    Publication date: January 19, 2017
    Inventor: Christopher W. Gabrys
  • Publication number: 20150360435
    Abstract: A process for assembling a corrugated pallet having of two die cut corrugated paperboard blanks that form a pallet top and a pallet bottom, with each having at least one vertically extending double thickness rib, each rib having at least one notch, wherein said notches lock the opposing ribs from opening when the pallet top and pallet bottom are vertically nested together. In performance of the process a mix of machine and human performed operations is used. The machine forms the rib on each blank by applying in-plane pressure to the blank through protruding elements on the machine that engage the blank and move in relation towards each other, and the machine maintains the in-plane pressure to keep the rib from opening until a time after the pallet top and bottom are nested together. The machine uses rib folding plates that apply out-of-plane forces to the blanks to assist forming of the ribs by rotating in the out-of-plane direction when the in-plane compression is applied.
    Type: Application
    Filed: June 16, 2014
    Publication date: December 17, 2015
    Inventors: Christopher W. Gabrys, Joseph J. Danko, E. Neil Schopke
  • Publication number: 20150284137
    Abstract: A corrugated paperboard pallet is produced from two flat blanks which comprise a pallet top and a pallet bottom. The two blanks are each folded to produce only two parallel vertically extending double thickness ribs, three horizontal panels, two vertical side walls and two horizontal flaps. The ribs of the pallet top and pallet bottom lock each other from opening in the center of the pallet by intersecting perpendicularly with notches in the ribs. The horizontal flaps lock the ribs from opening at the edges of the pallet by intersecting perpendicularly with notches, and the vertical sidewalls include vertical flaps that open inward defining fork passages whereby the vertical flaps lock said horizontal flaps from opening.
    Type: Application
    Filed: May 20, 2013
    Publication date: October 8, 2015
    Applicant: Lifdek Corporation
    Inventors: Douglas A. Olvey, James L. Sketo, Sean G. Gumbert, Christopher W. Gabrys
  • Publication number: 20150239609
    Abstract: A corrugated paperboard pallet is produced from two flat blanks which comprise a pallet top and a pallet bottom. The two blanks are each folded to produce only two parallel vertically extending double thickness ribs, three horizontal panels, two vertical side walls and two horizontal flaps. The ribs of the pallet top and pallet bottom lock each other from opening in the center of the pallet by intersecting perpendicularly with notches in the ribs. The horizontal flaps lock the ribs from opening at the edges of the pallet by intersecting perpendicularly with notches, and the vertical sidewalls include vertical flaps that open inward defining fork passages whereby the vertical flaps lock said horizontal flaps from opening.
    Type: Application
    Filed: December 23, 2014
    Publication date: August 27, 2015
    Inventors: Douglas A. Olvey, James L. Sketo, Sean G. Gumbert, Joseph J. Danko, Christopher W. Gabrys
  • Patent number: 8933607
    Abstract: An air core motor-generator has a rotor that rotates about an axis of rotation, and a stationary stator that magnetically applies torque to the rotor. The rotor includes magnetic poles that drive magnetic flux across an armature airgap. The stator has an air core armature located in the armature airgap, with windings such that the magnetic flux across the airgap penetrates directly transversely through the windings and induces an AC voltage in the windings as the rotor rotates. The armature windings are wound with wire that is assembled of a stack of multiple individually insulated ribbon conductors connected in parallel to form said wire. The ribbon conductors having a narrow thickness and a width substantially greater than said thickness. The armature is oriented in the airgap with the width of the ribbon conductors extending in the direction across the airgap and oriented parallel to the flux direction.
    Type: Grant
    Filed: January 18, 2006
    Date of Patent: January 13, 2015
    Assignee: Revolution Electric Motor Company, Inc.
    Inventor: Christopher W. Gabrys
  • Patent number: 7902700
    Abstract: A brushless permanent magnet motor has a rotor supported to rotate about an axis of rotation, and a stator that is stationary and magnetically exerts torque upon the rotor. The rotor has a ferromagnetic backiron and a circumferential array of alternating polarity magnetic poles that drive magnetic flux back and forth across an armature airgap. The stator includes an air core armature with windings made of bundled multiple individually insulated strand conductor wire. The windings are assembled together in a non-ferromagnetic structure that is located in the armature airgap, so alternating magnetic flux from the alternating polarity magnetic poles passes through the windings as the rotor rotates. A thin electrically conducting shield is located inside the armature airgap to increase the efficiency of the motor by reducing eddy current losses in the surfaces of the rotor magnets.
    Type: Grant
    Filed: April 3, 2007
    Date of Patent: March 8, 2011
    Inventor: Christopher W. Gabrys
  • Patent number: 7888839
    Abstract: A motor-generator includes a rotor that rotates about an axis of rotation, and a stator that is stationary and magnetically interacts with the rotor. The rotor is constructed of two spaced apart rotor portions having magnetic poles that drive magnetic flux across an armature airgap formed therebetween. An armature, located in the armature airgap, has a substantially nonmagnetic and low electrical conductivity form onto which wire windings are wound. The form has a free end that extends inside the rotor, and a support end that attaches to the stationary portion of the motor-generator. The form is constructed with a thin backing portion and thicker raised portions extending from the backing portion in the direction of the magnetic flux. The wire windings have multiple individually insulated conductor wire. The conductors of a single wire are electrically connected together in parallel and electrically insulated between each other along their length inside the armature airgap.
    Type: Grant
    Filed: March 14, 2005
    Date of Patent: February 15, 2011
    Assignee: Revolution Electric Motor Company, Inc.
    Inventors: Christopher W. Gabrys, Timothy S. Rodgers
  • Publication number: 20110031756
    Abstract: A Darrieus rotor supported by a bearing system to rotate about a vertical axis for capturing wind energy has an alternator that is directly-driven by the rotor and converts rotational power from the rotor into electrical power. An electronic controller controls the electrical load applied to the alternator and the power output from the alternator to an output. The alternator is constructed having a substantially constant reluctance torque for all angular positions of rotation of the rotor. The bearing system includes upper and lower rolling element mechanical bearings that provide radial support of the rotor against wind load and axial support of the rotor, and a magnetic bearing that provides axial lift that reduces the axial load on the mechanical bearings and reduces the starting torque for rotating the rotor.
    Type: Application
    Filed: December 10, 2008
    Publication date: February 10, 2011
    Applicant: WINDSPIRE ENERGY, INC.
    Inventor: Christopher W. Gabrys
  • Patent number: 7750515
    Abstract: A non-ventilated motor-generator includes a rotor supported for rotation on bearings inside a closed metal housing. The rotor is constructed of two spaced apart rotor sections having permanent magnets that drive magnetic flux across an air gap between the rotor sections. An air core armature in the air gap has windings in a non-magnetic structure that is structurally coupled to the housing. The armature is thinner than the armature air gap and is positioned such that there is a physical air gap on each side of the armature. The rotor has air flow passages through which air is induced to flow, in operation, in a polloidal loop that includes a portion that passes through the armature air gap, picking up heat from the armature, and a portion that is in contact with the inside of the motor-generator housing where the heat is transferred to the housing and dissipated to the atmosphere.
    Type: Grant
    Filed: October 19, 2006
    Date of Patent: July 6, 2010
    Inventor: Christopher W. Gabrys