Abstract: A method for treating magnetic material is provided. The method includes providing hard magnetic particles; increasing the magnetic coercivity of the hard magnetic particles by polishing the hard magnetic particles; and forming a permanent magnet, the permanent magnet including the polished hard magnetic particles.

Abstract: A method of monitoring a magnetic orientation of a composite magnetic material injected into a rotor pole of a rotor core. The rotor pole is defined by at least one rotor cavity. The method includes injecting a magnetic composite material into the at least one rotor cavity defining the rotor pole and applying an external magnetic field to the rotor pole to magnetically orient the magnetic composite material during injection into the at least one rotor cavity.

Abstract: A rotor core mold assembly including a rotor stack and a distribution plate. The rotor stack has a top surface and at least one rotor pole defined by a plurality of rotor stack cavities. Each of the plurality of rotor stack cavities has an aspect ratio defined by a width of a respective rotor stack cavity and a longitudinal length of the rotor stack. The distribution plate has a top surface and a bottom surface removably locatable on the top surface of the rotor stack to thereby form a fluid seal. The distribution plate includes a flow channel positioned on the top surface of the distribution plate and extending through the distribution plate, an injection gate in fluid communication with the flow channel, and a plurality of secondary flow channels coupled between the injection gate and the bottom surface of the distribution plate in fluid communication with the injection gate.

Abstract: A method for molding a magnetic material into a rotor stack, including providing a polymer melt including magnetic compound particles and a polymer binder, providing a rotor including a plurality of cavities, the rotor being arranged in a mold having a mold cavity surface, and providing a gap between the outer periphery of the rotor and the mold cavity surface. The method also includes filling a first volume of the polymer melt into the cavities of the rotor at a first pressure and filling a second volume of the polymer melt into the rotor at one or more second pressures, the one or more second pressures being less than the first pressure and above an ambient pressure.

Abstract: A rotor for an electric machine is disclosed, the rotor including a plurality of cavities filled with a magnetic material. In the disclosed rotor, the magnetic material includes Samarium-Iron-Nitrogen (Sm—Fe—N) particles, Manganese-Bismuth (Mn—Bi) particles, and a polymer binder. Performance characteristics of the magnetic material, such as following the rule of mixtures and exhibiting a linear relationship based on volume fraction of the Mn—Bi particles, is also disclosed.

Abstract: Electrically resistive devices, such as voltage dividers, and methods of making the same are disclosed. An illustrative voltage divider may include a substrate having an axis, an electrically resistive path applied to the substrate, and at least one terminal positioned around the substrate and in contact with the electrically resistive path. The electrically resistive path may include a primary resistor and a secondary resistor, with the primary resistor having a higher electrical resistance than the secondary resistor. An adjustable displacement of the at least one terminal along the axis of the substrate may allow adjustment of at least one electrical resistance associated with the at least one terminal. An adjustable tightness of the at least one terminal around the substrate may allow adjustment of the at least one electrical resistance associated with the at least one terminal.

Abstract: A system of additive manufacturing of an electronic component is provided. The system includes a deposition control computing device, the deposition control computing device including at least one processor in communication with at least one memory device. The at least one processor is programmed to generate control instructions of additive manufacturing of the electronic component, interpret the control instructions into controls of the system, and output the controls.

Abstract: A rotor of a synchronous reluctance motor may include: a plurality of laminations forming a stack, each lamination including: two parallel surfaces and a perimeter that define the lamination and a direction of stacking the laminations that is perpendicular to the parallel surfaces, the lamination at least partially filled with a magnetically soft electrical conductor and at least one cavity encircled by the conductor and extending from a first to a second surface of the two parallel surfaces, the conductor forming at least one bridge at the perimeter of the lamination from one side of the at least one cavity to another side of the at least one cavity. A value of a magnetic property and a value of a mechanical property of the at least one bridge differs from a value of the magnetic property and a value of the mechanical property of the conductor material.

Abstract: A permanent magnet motor is provided that produces variable magnetic flux. The motor may include two different types of permanent magnets with different coercivities. The magnetic state of one of the magnets may be altered during use. In one state, the effective magnetic flux of the motor is greater, and in another state, the effective magnetic flux of the motor is less.

Abstract: A method for additive manufacturing of an article having a controlled magnetic anisotropy includes: forming a metallic layer of the article using additive manufacturing, the metallic layer having a magnetic anisotropy aligned in a first direction; forming a subsequent metallic layer of the article using additive manufacturing, the subsequent metallic layer having the magnetic anisotropy aligned in a second direction different from the first direction; and repeating the forming of subsequent metallic layers of the article to form at least a portion of the article, each subsequent metallic layer having the magnetic anisotropy aligned in a different direction than a previous metallic layer.

Abstract: Electrically resistive devices, such as voltage dividers, and methods of making the same are disclosed. An illustrative voltage divider may include a substrate having an axis, an electrically resistive path applied to the substrate, and at least one terminal positioned around the substrate and in contact with the electrically resistive path. The electrically resistive path may include a primary resistor and a secondary resistor, with the primary resistor having a higher electrical resistance than the secondary resistor. An adjustable displacement of the at least one terminal along the axis of the substrate may allow adjustment of at least one electrical resistance associated with the at least one terminal. An adjustable tightness of the at least one terminal around the substrate may allow adjustment of the at least one electrical resistance associated with the at least one terminal.

Abstract: The rotor of a rotor assembly for an electric machine includes first magnetic structures utilized for torque production in the electric machine. Second magnetic structures including second magnetic poles not utilized for torque production in the electric machine are polymer-bonded to at least one of the rotor and the rotor shaft.

Abstract: A method for forming an article of manufacture using additive manufacturing, includes: a processor executing program instructions to: (a) rotate an object continuously about a horizontal axis using a first rotational stage, wherein the object is partially submerged in a bath of energy curable liquid formulation during the rotation; (b) control a rate of rotation of the object to achieve a desired radial thickness of a sub layer of uncured liquid formulation at a desired rotational location on the object; (c) direct an energy source to provide an energy dose onto the object at a desired rotational location, wherein the energy dose is configured to cure and solidify the sub layer; and repeat (a), (b) and (c) until a desired radial thickness of a cured liquid formulation layer is a achieved.

Abstract: A method of balancing a rotor and/or fixing rotor components includes arranging a plurality of generally like laminations side by side in a stack to form at least a part of a rotor. The rotor has a rotational center axis and each of the laminations having a plurality of apertures that cooperate to form passages that extend axially along a length of the stack. In accordance with an aspect of the method, a polymer based fixation material is filled in the passages in a manner to fix the laminations together in the stack. With the fixation material, a sprue is formed, projecting from an axial face of the stack. In accordance with another aspect of the method, a weight of the sprue is adjusted to rotationally balance the rotor about the rotor center axis.

Abstract: The rotor of a rotor assembly for an electric machine includes first magnetic structures utilized for torque production in the electric machine. Second magnetic structures including second magnetic poles not utilized for torque production in the electric machine are polymer-bonded to at least one of the rotor and the rotor shaft.

Abstract: A method for additive manufacturing of an article having a controlled magnetic anisotropy includes: forming a metallic layer of the article using additive manufacturing, the metallic layer having a magnetic anisotropy aligned in a first direction; forming a subsequent metallic layer of the article using additive manufacturing, the subsequent metallic layer having the magnetic anisotropy aligned in a second direction different from the first direction; and repeating the forming of subsequent metallic layers of the article to form at least a portion of the article, each subsequent metallic layer having the magnetic anisotropy aligned in a different direction than a previous metallic layer

Abstract: A method for operating an electrical machine having a stator and having a rotor with permanent magnets, includes: running the electrical machine; determining, while performing the running of the electrical machine, whether the permanent magnets have been demagnetized; finding, while running the electrical machine, the q-axis responsive to a determination that the permanent magnets have been demagnetized; firing a current pulse through the stator, while running the electrical machine, when the q-axis reaches a desired position relative to a selected stator phase, wherein the current pulse is constructed to remagnetize the permanent magnets; and continuing to run the electrical machine.

Abstract: A multi-layered conductor comprising one or more conductor layers of an electrically conductive material and one or more shielding layers of a soft magnetic material. The shielding layer can be coated onto the conductor layer and has a lower conductivity and a higher magnetic permeability than the electrically conductive material of conductor layers. The shielding layer can, at least when alternating current (AC) flows through the multi-layered conductor at relatively high frequencies, provide a separate power path for at least a portion of the high frequency AC current, as well as absorb at least a portion of the high frequency noises associated with that separated high frequency AC current. Additionally, the shielding layer can be separated from the conductor layer at an output end of the multi-layered conductor so that output ends of the shielding layer and conductor layer can be electrically connected to different electrical devices or components.

Abstract: A multi-layered conductor comprising one or more conductor layers of an electrically conductive material and one or more shielding layers of a soft magnetic material. The shielding layer can be coated onto the conductor layer and has a lower conductivity and a higher magnetic permeability than the electrically conductive material of conductor layers. The shielding layer can, at least when alternating current (AC) flows through the multi-layered conductor at relatively high frequencies, provide a separate power path for at least a portion of the high frequency AC current, as well as absorb at least a portion of the high frequency noises associated with that separated high frequency AC current. Additionally, the shielding layer can be separated from the conductor layer at an output end of the multi-layered conductor so that output ends of the shielding layer and conductor layer can be electrically connected to different electrical devices or components.

Abstract: A method for forming an article of manufacture using additive manufacturing, includes: a processor executing program instructions to: (a) rotate an object continuously about a horizontal axis using a first rotational stage, wherein the object is partially submerged in a bath of energy curable liquid formulation during the rotation; (b) control a rate of rotation of the object to achieve a desired radial thickness of a sub layer of uncured liquid formulation at a desired rotational location on the object; (c) direct an energy source to provide an energy dose onto the object at a desired rotational location, wherein the energy dose is configured to cure and solidify the sub layer; and repeat (a), (b) and (c) until a desired radial thickness of a cured liquid formulation layer is a achieved.