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).

  • Patent number: 10770940
    Abstract: 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: Grant
    Filed: January 31, 2017
    Date of Patent: September 8, 2020
    Assignee: Regal Beloit Australia Pty Ltd.
    Inventors: Mark Thiele, Greg Heins, Matthew J. Turner, Dean James Patterson
  • Patent number: 10594180
    Abstract: 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: Grant
    Filed: January 31, 2017
    Date of Patent: March 17, 2020
    Assignee: Regal Beloit America, Inc.
    Inventors: Greg Heins, Mark Thiele, Dean James Patterson, Matthew J. Turner
  • Patent number: 10541591
    Abstract: 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: Grant
    Filed: January 31, 2017
    Date of Patent: January 21, 2020
    Assignee: REGAL BELOIT AUSTRALIA PTY, LTD.
    Inventors: Dean James Patterson, Mark Thiele, Greg Heins, Matthew J. Turner
  • Patent number: 10447102
    Abstract: 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: Grant
    Filed: March 15, 2013
    Date of Patent: October 15, 2019
    Assignee: Regal Beloit Australia Pty. Ltd.
    Inventors: Dean James Patterson, Rafal Pawel Rohoza, Steven Peter Camilleri, Matthew Turner, Charles Richard Langford
  • Publication number: 20180219442
    Abstract: 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: Application
    Filed: January 31, 2017
    Publication date: August 2, 2018
    Inventors: Greg Heins, Mark Thiele, Dean James Patterson, Matthew J. Turner
  • Publication number: 20180219434
    Abstract: 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: Application
    Filed: January 31, 2017
    Publication date: August 2, 2018
    Inventors: Dean James Patterson, Mark Thiele, Greg Heins, Matthew J. Turner
  • Publication number: 20180219441
    Abstract: 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: Application
    Filed: January 31, 2017
    Publication date: August 2, 2018
    Inventors: Mark Thiele, Greg Heins, Matthew J. Turner, Dean James Patterson
  • Patent number: 9467015
    Abstract: 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: Grant
    Filed: November 1, 2013
    Date of Patent: October 11, 2016
    Assignee: Regal Beloit Australia Pty Ltd.
    Inventors: Charles Richard Langford, Steven Peter Camilleri, Dean James Patterson
  • Patent number: 9391500
    Abstract: 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: Grant
    Filed: March 22, 2011
    Date of Patent: July 12, 2016
    Assignee: 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
  • Publication number: 20140265700
    Abstract: 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: Application
    Filed: March 15, 2013
    Publication date: September 18, 2014
    Applicant: Regal Beloit Australia PTY LTD
    Inventors: Dean James Patterson, Rafal Pawel Rohoza, Steven Peter Camilleri, Matthew Turner, Charles Richard Langford
  • Publication number: 20140062246
    Abstract: 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: Application
    Filed: November 1, 2013
    Publication date: March 6, 2014
    Applicant: IN MOTION TECHNOLOGIES PTY., LTD.
    Inventors: Charles Richard Langford, Steven Peter Camilleri, Dean James Patterson
  • Patent number: 8598761
    Abstract: 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: Grant
    Filed: April 29, 2008
    Date of Patent: December 3, 2013
    Assignee: In Motion Technologies Pty., Ltd.
    Inventors: Charles Richard Langford, Steven Peter Camilleri, Dean James Patterson
  • Publication number: 20130069467
    Abstract: 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: Application
    Filed: March 22, 2011
    Publication date: March 21, 2013
    Applicant: REGAL BELOIT CORPORATION
    Inventors: Michael D. Smith, William A. Ziegler, Michael Garrett, Dean James Patterson, Roger C. Becerra, Ludovic Chretien, Darrel Buttram, Steven Peter Camilleri
  • Publication number: 20130057105
    Abstract: 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: Application
    Filed: September 2, 2011
    Publication date: March 7, 2013
    Inventors: Dean James Patterson, Steven Stretz, William Stadler, Alan W. Yeadon
  • Patent number: 8061171
    Abstract: 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: Grant
    Filed: December 16, 2009
    Date of Patent: November 22, 2011
    Assignee: In Motion Technologies
    Inventors: Dean James Patterson, Steven Peter Camilleri, Lyell Douglas Embery
  • Publication number: 20100164316
    Abstract: 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: Application
    Filed: April 29, 2008
    Publication date: July 1, 2010
    Applicant: IN MOTION TECHNOLOGIES PTY LIMITED
    Inventors: Charles Richard Langford, Steven Peter Camilleri, Dean James Patterson
  • Publication number: 20100139353
    Abstract: 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: Application
    Filed: December 16, 2009
    Publication date: June 10, 2010
    Applicant: IN MOTION TECHNOLOGIES PTY. LTD.
    Inventors: Dean James Patterson, Steven Peter Camilleri, Lyell Douglas Embery
  • Patent number: 7654123
    Abstract: 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: Grant
    Filed: February 3, 2005
    Date of Patent: February 2, 2010
    Assignee: In Motion Technologies Pty. Ltd.
    Inventors: Dean James Patterson, Steven Peter Camilleri, Lyell Douglas Embery
  • Patent number: 7521834
    Abstract: A poly-phase electromagnetic device having n winding phases (n>2) wherein each phase is made from a single conductor strand wound in a lap form configuration. The windings are configured such that on assembly to a slotted magnetically conducive base a maximum of n?1 end turns overlapping is achieved so that the slot packing density can be optimized. The preferred configurations also enable neat and compact terminations which facilitates efficient packaging of the completed device. The windings are made either from discrete bobbins which are electrically interconnected upon assembly to the base, or alternatively from strings of continuously formed sub-windings. The latter process in particular enables full or partial automation of the winding and/or assembly process.
    Type: Grant
    Filed: November 13, 2003
    Date of Patent: April 21, 2009
    Inventors: Dean James Patterson, Byron John Kennedy, Steven Peter Camilleri, Benjamin David Guymer, Matthew Campbell Greaves
  • Publication number: 20080148794
    Abstract: 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: Application
    Filed: February 3, 2005
    Publication date: June 26, 2008
    Applicant: IN MOTION TECHNOLOGIES
    Inventors: Dean James Patterson, Steven Peter Camilleri, Lyell Douglas Embery