Patents by Inventor David G. Calley
David G. 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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Patent number: 8994243Abstract: An electrical machine stator assembly comprises: an electroconductive coil arranged circumferentially with respect to the rotational axis; a plurality of pairs of side lamination assemblies arranged circumferentially with respect to the rotational axis; a plurality of pairs of switch lamination assemblies arranged circumferentially with respect to the rotational axis and positioned adjacent ends of side lamination assemblies proximal the rotor; and at least one tooth associated with each switch lamination assembly and proximal the rotor. Each switch lamination assembly comprises a first group of laminated materials aligned generally circumferentially and generally in a first direction with respect to the rotational axis, the first direction being one selected from the group consisting of the axial and radial directions with respect to the rotational axis.Type: GrantFiled: November 7, 2012Date of Patent: March 31, 2015Assignee: Electric Torque Machines IncInventors: David G. Calley, John M. Dyer, Thomas F. Janecek, Tyler K. Williams
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Patent number: 8952590Abstract: Electrical machines, for example transverse flux machines and/or commutated flux machines, may be configured to achieve increased efficiency, increased output torque, and/or reduced operating losses via use of laminated materials in connection with powdered metal materials. For example, stacks of laminated materials may be coupled to powdered metal teeth to form portions of a stator in an electrical machine.Type: GrantFiled: November 8, 2011Date of Patent: February 10, 2015Assignee: Electric Torque Machines IncInventors: David G. Calley, Daniel S. Cole, John M. Dyer, Thomas F. Janecek, Tyler K. Williams
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Patent number: 8836196Abstract: Electrical machines, for example transverse flux machines and/or commutated flux machines, may be configured to achieve increased efficiency, increased output torque, and/or reduced operating losses via use of laminated materials, for example laminated materials configured with cuts and/or segmentations. Segmentations may also assist with manufacturability, mechanical retention of components, and the like.Type: GrantFiled: March 12, 2013Date of Patent: September 16, 2014Assignee: Electric Torque Machines, Inc.Inventors: David G. Calley, Daniel S. Cole, John M. Dyer, Thomas F. Janecek, Tyler K. Williams
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Patent number: 8760023Abstract: Electrical machines, for example transverse flux machines and/or commutated flux machines, may be configured to achieve reduced overall cogging torque via implementation of a sixth-phase offset. Individual cogging torque waveforms in the electrical machine may be evenly distributed across one-sixth of a voltage phase or other suitable spacing, resulting in a reduced magnitude and/or increased sinusoidality of the overall cogging torque waveform for the electrical machine.Type: GrantFiled: July 17, 2012Date of Patent: June 24, 2014Assignee: Electric Torque Machines, Inc.Inventors: David G. Calley, Daniel S. Cole, John M. Dyer, Thomas F. Janecek
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Patent number: 8749108Abstract: An electrical machine comprising a rotor, a coil and a stator comprising a lamination stack coupled to a tooth, wherein the electrical machine is at least one of a transversal flux machine is described. The electrical machine may be a transversal flux machine such as a transverse or commutated flux machine. A lamination ring is described comprising a plurality of lamination stacks. A lamination stack may comprise a plurality of trenches configured to retain a plurality of teeth. The tooth may comprise a portion of the switching surface, and a portion of a lamination stack may extend to the surface of the tooth to make up a portion of the switching surface. The electrical machine may be configured with a constant air gap, wherein no more than 15% variability in the distance between the stator switching surface and the rotor switching surface.Type: GrantFiled: March 14, 2012Date of Patent: June 10, 2014Assignee: Electric Torque Machines, Inc.Inventors: John M. Dyer, Thomas F. Janecek, David G. Calley, Daniel S. Cole, Tyler K. Williams
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Publication number: 20130264905Abstract: Electrical machines, for example transverse flux machines and/or commutated flux machines, may be configured to achieve increased efficiency, increased output torque, and/or reduced operating losses via use of laminated materials, for example laminated materials configured with cuts and/or segmentations. Segmentations may also assist with manufacturability, mechanical retention of components, and the like.Type: ApplicationFiled: March 12, 2013Publication date: October 10, 2013Applicant: Electric Torque Machines, Inc.Inventors: David G. Calley, Daniel S. Cole, John M. Dyer, Thomas F. Janecek, Tyler K. Williams
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Publication number: 20130169096Abstract: Electrical machines, for example transverse flux machines and/or commutated flux machines, may be configured to achieve reduced overall cogging torque via implementation of a sixth-phase offset. Individual cogging torque waveforms in the electrical machine may be evenly distributed across one-sixth of a voltage phase or other suitable spacing, resulting in a reduced magnitude and/or increased sinusoidality of the overall cogging torque waveform for the electrical machine.Type: ApplicationFiled: July 17, 2012Publication date: July 4, 2013Applicant: ELECTRIC TORQUE MACHINES INC.Inventors: David G. Calley, Daniel S. Cole, John M. Dyer, Thomas F. Janecek
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Patent number: 8415848Abstract: Electrical machines, for example transverse flux machines and/or commutated flux machines, may be configured to achieve increased efficiency, increased output torque, and/or reduced operating losses via use of extended magnets, overhung rotors, and/or stator tooth overlap. Extended magnets may reduce flux leakage between adjacent flux concentrators. Overhung rotors may reduce flux leakage, and may also facilitate voltage balancing in polyphase devices. Stator tooth overlap may reduce hysteresis losses, for example losses in flux concentrating portions of an electrical machine.Type: GrantFiled: October 12, 2011Date of Patent: April 9, 2013Assignee: Electric Torque Machines, Inc.Inventors: David G. Calley, Daniel S Cole, John M. Dyer, Thomas F. Janecek
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Patent number: 8405275Abstract: Electrical machines, for example transverse flux machines and/or commutated flux machines, may be configured to achieve increased efficiency, increased output torque, and/or reduced operating losses via use of laminated materials, for example laminated materials configured with cuts and/or segmentations. Segmentations may also assist with manufacturability, mechanical retention of components, and the like.Type: GrantFiled: November 8, 2011Date of Patent: March 26, 2013Assignee: Electric Torque Machines, Inc.Inventors: David G. Calley, Daniel S. Cole, John M. Dyer, Thomas F. Janecek, Tyler K. Williams
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Patent number: 8395291Abstract: Electrical machines, for example transverse flux machines and/or commutated flux machines, may be configured to be coupled to an electric bicycle or other light electric vehicle. Certain exemplary electrical machines may be configured with a high torque density and/or lower operating losses, providing improved operational characteristics to an e-bike. Moreover, certain exemplary electrical machines may replace a gear cassette on a bicycle, allowing conversion of the bicycle from manual to electric operation.Type: GrantFiled: May 3, 2010Date of Patent: March 12, 2013Assignee: Electric Torque Machines, Inc.Inventors: David G. Calley, Daniel S. Cole, John M. Dyer, Thomas F. Janecek, J. Scott Reynolds
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Publication number: 20120235519Abstract: An electrical machine comprising a rotor, a coil and a stator comprising a lamination stack coupled to a tooth, wherein the electrical machine is at least one of a transversal flux machine is described. The electrical machine may be a transversal flux machine such as a transverse or commutated flux machine. A lamination ring is described comprising a plurality of lamination stacks. A lamination stack may comprise a plurality of trenches configured to retain a plurality of teeth. The tooth may comprise a portion of the switching surface, and a portion of a lamination stack may extend to the surface of the tooth to make up a portion of the switching surface. The electrical machine may be configured with a constant air gap, wherein no more than 15% variability in the distance between the stator switching surface and the rotor switching surface.Type: ApplicationFiled: March 14, 2012Publication date: September 20, 2012Applicant: MOTOR EXCELLENCE LLCInventors: John M. Dyer, Thomas F. Janecek, David G. Calley, Daniel S. Cole, Tyler K. Williams
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Patent number: 8242658Abstract: Disclosed are transverse and/or commutated flux machines and components thereof, and methods of making and using the same. Certain rotors for use in transverse and commutated flux machines may be formed to facilitate a “many to many” flux switch configuration between flux concentrating stator portions having opposite polarities. Other rotors may be formed from a first material, and contain flux switches formed from a second material. Yet other rotors may be machined, pressed, stamped, folded, and/or otherwise mechanically formed. Via use of such rotors, transverse and/or commutated flux machines can achieve improved performance, efficiency, and/or be sized or otherwise configured for various applications.Type: GrantFiled: September 12, 2011Date of Patent: August 14, 2012Assignee: Electric Torque Machines Inc.Inventors: David G. Calley, Thomas F. Janecek
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Patent number: 8222786Abstract: Electrical machines, for example transverse flux machines and/or commutated flux machines, may be configured to achieve reduced overall cogging torque via implementation of a sixth-phase offset. Individual cogging torque waveforms in the electrical machine may be evenly distributed across one-sixth of a voltage phase or other suitable spacing, resulting in a reduced magnitude and/or increased sinusoidality of the overall cogging torque waveform for the electrical machine.Type: GrantFiled: May 3, 2010Date of Patent: July 17, 2012Assignee: Motor Excellence LLCInventors: David G. Calley, Daniel S Cole, John M. Dyer, Thomas F. Janecek
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Patent number: 8193679Abstract: Disclosed are single- and poly-phase transverse and/or commutated flux machines and components thereof, and methods of making and using the same. Exemplary devices, including polyphase devices, may variously be configured with an interior rotor and/or an interior stator. Other exemplary devices, including polyphase devices, may be configured in a slim, stacked, and/or nested configuration. Via use of such polyphase configurations, transverse and/or commutated flux machines can achieve improved performance, efficiency, and/or be sized or otherwise configured for various applications.Type: GrantFiled: June 30, 2011Date of Patent: June 5, 2012Assignee: Motor Excellence LLCInventors: David G. Calley, Thomas F. Janecek
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Publication number: 20120119610Abstract: Electrical machines, for example transverse flux machines and/or commutated flux machines, may be configured to achieve increased efficiency, increased output torque, and/or reduced operating losses via use of laminated materials, for example laminated materials configured with cuts and/or segmentations. Segmentations may also assist with manufacturability, mechanical retention of components, and the like.Type: ApplicationFiled: November 8, 2011Publication date: May 17, 2012Applicant: Motor Excellence, LLCInventors: David G. Calley, Daniel S. Cole, John M. Dyer, Thomas F. Janecek, Tyler K. Williams
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Publication number: 20120119599Abstract: Electrical machines, for example transverse flux machines and/or commutated flux machines, may be configured to achieve increased efficiency, increased output torque, and/or reduced operating losses via use of laminated materials in connection with powdered metal materials. For example, stacks of laminated materials may be coupled to powdered metal teeth to form portions of a stator in an electrical machine.Type: ApplicationFiled: November 8, 2011Publication date: May 17, 2012Applicant: MOTOR EXCELLENCE, LLCInventors: David G. Calley, Daniel S. Cole, John M. Dyer, Thomas F. Janecek, Tyler K. Williams
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Publication number: 20120025637Abstract: Electrical machines, for example transverse flux machines and/or commutated flux machines, may be configured to achieve increased efficiency, increased output torque, and/or reduced operating losses via use of extended magnets, overhung rotors, and/or stator tooth overlap. Extended magnets may reduce flux leakage between adjacent flux concentrators. Overhung rotors may reduce flux leakage, and may also facilitate voltage balancing in polyphase devices. Stator tooth overlap may reduce hysteresis losses, for example losses in flux concentrating portions of an electrical machine.Type: ApplicationFiled: October 12, 2011Publication date: February 2, 2012Applicant: MOTOR EXCELLENCE LLCInventors: David G. Calley, Daniel S. Cole, John M. Dyer, Thomas F. Janecek
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Publication number: 20120001501Abstract: Disclosed are transverse and/or commutated flux machines and components thereof, and methods of making and using the same. Certain rotors for use in transverse and commutated flux machines may be formed to facilitate a “many to many” flux switch configuration between flux concentrating stator portions having opposite polarities. Other rotors may be formed from a first material, and contain flux switches formed from a second material. Yet other rotors may be machined, pressed, stamped, folded, and/or otherwise mechanically formed. Via use of such rotors, transverse and/or commutated flux machines can achieve improved performance, efficiency, and/or be sized or otherwise configured for various applications.Type: ApplicationFiled: September 12, 2011Publication date: January 5, 2012Applicant: MOTOR EXCELLENCE, LLCInventors: David G. Calley, Thomas F. Janecek
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Publication number: 20110273035Abstract: Disclosed are transverse and/or commutated flux machines and components thereof, and methods of making and using the same. Certain exemplary stators for use in transverse and commutated flux machines may be configured with gaps therebetween, for example in order to counteract tolerance stackup. Other exemplary stators may be configured as partial stators having a limited number of magnets and/or flux concentrators thereon. Partial stators may facilitate ease of assembly and/or use with various rotors. Additionally, exemplary floating stators can allow a transverse and/or commutated flux machine to utilize an air gap independent of the diameter of a rotor. Via use of such exemplary stators, transverse and/or commutated flux machines can achieve improved performance, efficiency, and/or be sized or otherwise configured for various applications.Type: ApplicationFiled: July 21, 2011Publication date: November 10, 2011Applicant: MOTOR EXCELLENCE, LLCInventors: David G. Calley, Thomas F. Janecek
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Patent number: 8053944Abstract: Electrical machines, for example transverse flux machines and/or commutated flux machines, may be configured to achieve increased efficiency, increased output torque, and/or reduced operating losses via use of extended magnets, overhung rotors, and/or stator tooth overlap. Extended magnets may reduce flux leakage between adjacent flux concentrators. Overhung rotors may reduce flux leakage, and may also facilitate voltage balancing in polyphase devices. Stator tooth overlap may reduce hysteresis losses, for example losses in flux concentrating portions of an electrical machine.Type: GrantFiled: May 3, 2010Date of Patent: November 8, 2011Assignee: Motor Excellence, LLCInventors: David G. Calley, Daniel S Cole, John M. Dyer, Thomas F. Janecek