Patents by Inventor David Calley
David Calley 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: 20250023400Abstract: An electric machine, which may operate as an electric motor or generator, that address performance and manufacturing shortcomings in various motor design approaches particularly transverse flux, axial and radial flux motors with higher torque, higher RPM, and lower core losses and lower cogging. An exemplary electric machine incorporates shape monolithic components such as the armature teeth or connector ring, armature ring, concentrator teeth or concentrator ring formed by Soft metal Composite (SMC). Magnets may be configured between the concentrator teeth to form a magnet ring having a plurality of magnetic poles. The armature flux paths may be shared between phases. The air gaps may be axial and extend between armature teeth and concentrator teeth and the magnetic poles configured between the concentrator teeth. The armature, concentrator teeth and magnetic poles may extend radially and alternate along the axial axis of the electric machine, producing axial and/or radial airgaps.Type: ApplicationFiled: September 27, 2024Publication date: January 16, 2025Inventor: David Calley
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Patent number: 12119708Abstract: An electric machine, which may operate as an electric motor or generator, that address performance and manufacturing shortcomings in various motor design approaches particularly transverse flux, axial and radial flux motors with higher torque, higher RPM, and lower core losses and lower cogging. An exemplary electric machine incorporates shape monolithic components such as the armature teeth or connector ring, armature ring, concentrator teeth or concentrator ring formed by Soft metal Composite (SMC). Magnets may be configured between the concentrator teeth to form a magnet ring having a plurality of magnetic poles. The armature flux paths may be shared between phases. The air gaps may be axial and extend between armature teeth and concentrator teeth and the magnetic poles configured between the concentrator teeth. The armature, concentrator teeth and magnetic poles may extend radially and alternate along the axial axis of the electric machine, producing axial and/or radial airgaps.Type: GrantFiled: March 18, 2021Date of Patent: October 15, 2024Assignee: Elemental Motors, LLCInventor: David Calley
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Publication number: 20230069099Abstract: An electric machine, which may operate as an electric motor or generator, that address performance and manufacturing shortcomings in various motor design approaches particularly transverse flux, axial and radial flux motors with higher torque, higher RPM, and lower core losses and lower cogging. An exemplary electric machine incorporates shape monolithic components such as the armature teeth or connector ring, armature ring, concentrator teeth or concentrator ring formed by Soft metal Composite (SMC). Magnets may be configured between the concentrator teeth to form a magnet ring having a plurality of magnetic poles. The armature flux paths may be shared between phases. The air gaps may be axial and extend between armature teeth and concentrator teeth and the magnetic poles configured between the concentrator teeth. The armature, concentrator teeth and magnetic poles may extend radially and alternate along the axial axis of the electric machine, producing axial and/or radial airgaps.Type: ApplicationFiled: March 18, 2021Publication date: March 2, 2023Inventor: David Calley
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Patent number: 11260936Abstract: A human power conversion system incorporates two or more electric machines to aid in the powering of a vehicle through energy conversion. A first electric machine is coupled with the human powered input and acts as a generator when a human power input is not sufficient to produce electrical power that is provided to a second electric machine that propels the vehicle. The vehicle may be a bicycle and the first electric machine may be coupled to the crank. A bi-coupled electric machine including the first and second electric machines with a common rotor or stator may be employed and coupled to the crank and/or the driven wheel. Power produced by the first electric machine may be provided directly to the second machine or may be stored in a battery and used to propel the vehicle or power other electronic components.Type: GrantFiled: July 31, 2019Date of Patent: March 1, 2022Inventors: David Calley, Steve Purcell
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Patent number: 11081913Abstract: A stator made from a ribbon of metal having multiple layers of slit metal, and motors made therefrom are described. A ribbon having multiple layers of metal is formed into a stator such as by flattening or pleating the ribbon to form each pole of a stator having a plurality of stator teeth, or poles. The stator formed from the metal ribbon may be configured into any suitable type of motor, such as an axial transverse flu motor. A magnetic flu return may also be made out of metal ribbon.Type: GrantFiled: April 23, 2019Date of Patent: August 3, 2021Assignee: Moog Inc.Inventor: David Calley
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Publication number: 20210031873Abstract: A human power conversion system incorporates two or more electric machines to aid in the powering of a vehicle through energy conversion. A first electric machine is coupled with the human powered input and acts as a generator when a human power input is not sufficient to produce electrical power that is provided to a second electric machine that propels the vehicle. The vehicle may be a bicycle and the first electric machine may be coupled to the crank. A bi-coupled electric machine including the first and second electric machines with a common rotor or stator may be employed and coupled to the crank and/or the driven wheel. Power produced by the first electric machine may be provided directly to the second machine or may be stored in a battery and used to propel the vehicle or power other electronic components.Type: ApplicationFiled: July 31, 2019Publication date: February 4, 2021Inventors: David Calley, Steve Purcell
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Publication number: 20190252928Abstract: A stator made from a ribbon of metal having multiple layers of slit metal, and motors made therefrom are described. A ribbon having multiple layers of metal is formed into a stator such as by flattening or pleating the ribbon to form each pole of a stator having a plurality of stator teeth, or poles. The stator formed from the metal ribbon may be configured into any suitable type of motor, such as an axial transverse flu motor. A magnetic flu return may also be made out of metal ribbon.Type: ApplicationFiled: April 23, 2019Publication date: August 15, 2019Inventor: David Calley
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Patent number: 10320246Abstract: A stator made from a ribbon of metal having multiple layers of slit metal, and motors made therefrom are described. A ribbon having multiple layers of metal is formed into a stator such as by flattening or pleating the ribbon to form each pole of a stator having a plurality of stator teeth, or poles. The stator formed from the metal ribbon may be configured into any suitable type of motor, such as an axial transverse flu motor. A magnetic flu return may also be made out of metal ribbon.Type: GrantFiled: November 30, 2016Date of Patent: June 11, 2019Assignee: Moog Inc.Inventor: David Calley
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Publication number: 20170250579Abstract: A stator made from a ribbon of metal having multiple layers of slit metal, and motors made therefrom are described. A ribbon having multiple layers of metal is formed into a stator such as by flattening or pleating the ribbon to form each pole of a stator having a plurality of stator teeth, or poles. The stator formed from the metal ribbon may be configured into any suitable type of motor, such as an axial transverse flu motor. A magnetic flu return may also be made out of metal ribbon.Type: ApplicationFiled: November 30, 2016Publication date: August 31, 2017Inventor: David Calley
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Patent number: 9680339Abstract: A stator made from a ribbon of metal having multiple layers of slit metal, and motors made therefrom are described. A ribbon having multiple layers of metal is formed into a stator such as by flattening or pleating the ribbon to form each pole of a stator having a plurality of stator teeth, or poles. The stator formed from the metal ribbon may be configured into any suitable type of motor, such as an axial transverse flux motor. A magnetic flux return may also be made out of metal ribbon.Type: GrantFiled: January 6, 2014Date of Patent: June 13, 2017Assignee: Moog Inc.Inventor: David Calley
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Publication number: 20150340912Abstract: A stator made from a ribbon of metal having multiple layers of slit metal, and motors made therefrom are described. A ribbon having multiple layers of metal is formed into a stator such as by flattening or pleating the ribbon to form each pole of a stator having a plurality of stator teeth, or poles. The stator formed from the metal ribbon may be configured into any suitable type of motor, such as an axial transverse flu motor. A magnetic flu return may also be made out of metal ribbon.Type: ApplicationFiled: January 6, 2014Publication date: November 26, 2015Inventor: David CALLEY
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Patent number: 8840131Abstract: A three-wheeled vehicle having an arrangement of wheels with two forward wheels and one back wheel and a profile adjustment feature is described. The back wheel may be configured as the steering wheel, and in some cases is the only steering wheel. The two forward wheels are configured essentially parallel with each other and the back wheel is configured essentially centered between and back from the two forward wheels. This arrangement of the wheels provides for a stability that does not require a person to maintain balance to keep the vehicle in an upright position. The profile adjustment feature may automatically adjust the height of the vehicle as a function of vehicle speed. As the vehicle speeds up, the height may be reduce to provide a more stable vehicle that is turned more by tilting the vehicle than by turning the back wheel.Type: GrantFiled: March 15, 2013Date of Patent: September 23, 2014Assignee: Planet Rider LLCInventor: David Calley
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Publication number: 20140262578Abstract: A three-wheeled vehicle having an arrangement of wheels with two forward wheels and one back wheel and a profile adjustment feature is described. The back wheel may be configured as the steering wheel, and in some cases is the only steering wheel. The two forward wheels are configured essentially parallel with each other and the back wheel is configured essentially centered between and back from the two forward wheels. This arrangement of the wheels provides for a stability that does not require a person to maintain balance to keep the vehicle in an upright position. The profile adjustment feature may automatically adjust the height of the vehicle as a function of vehicle speed. As the vehicle speeds up, the height may be reduce to provide a more stable vehicle that is turned more by tilting the vehicle than by turning the back wheel.Type: ApplicationFiled: March 15, 2013Publication date: September 18, 2014Inventor: David Calley
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Publication number: 20080101916Abstract: Methods and systems for improving stall controlled wind turbine effectiveness by accurately determining wind speed without using an anemometer or other independent wind speed measuring device. Wind speed may be determined, among other methods, by tracking a mapped TSR model with respect to an operating stall controlled wind turbine in a given TSR range; decreasing a Ramp Start RPM value upon reaching a maximum desired power level and by following a mapped RPM into ramp (the control going into RS) for the desired wind speed range; upon reaching a desired RPM level, raising the RPM with power; and/or using periodic unloading of the rotor. The wind speed information may be utilized to control wind turbine parameters.Type: ApplicationFiled: October 22, 2007Publication date: May 1, 2008Inventor: David Calley
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Publication number: 20070013194Abstract: A variable voltage and frequency output wind turbine. Variations of the wind turbine include use of a slotless alternator to reduce alternator noise, a high power AC output to facilitate transmission of the output over extended distances, AC to DC converters and DC to AC converters, and sensors for systems and devices to receive the wind turbine output and to allow matching of the output to the receiving devices and system. Other features include a removable hatchcover for dissipating heat from components contained in the turbine or attached to the hatchcover, a swept blade design to reduce blade-produced noise, and power storage components for storing and intermittently using energy stored as a result of wind turbine power generation.Type: ApplicationFiled: July 17, 2006Publication date: January 18, 2007Inventor: David Calley
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Patent number: 6924579Abstract: A motor/alternator is formed by a single toroidal magnet and flux conductors which, in combination with flux switches, create an alternating magnetic circuit around a power coil. The motor/alternator geometry minimizes flux leakage. The form of the flux conductor and flux switch terminations allows for a high number of poles and reduces magnetic reluctance.Type: GrantFiled: November 25, 2003Date of Patent: August 2, 2005Inventor: David Calley
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Publication number: 20040150288Abstract: A motor/alternator is formed by a single toroidal magnet and flux conductors which, in combination with flux switches, create an alternating magnetic circuit around a power coil. The motor/alternator geometry minimizes flux leakage. The form of the flux conductor and flux switch terminations allows for a high number of poles and reduces magnetic reluctance.Type: ApplicationFiled: November 25, 2003Publication date: August 5, 2004Inventor: David Calley