Abstract: A permanent magnet rotor for a dc brushless motor generally comprised of a non-insulated shaft and and a permanent magnet is formed in one embodiment by compacting a powdered permanent magnet material substantially about a non-insulated shaft of relatively incompressible material utilizing dynamic magnetic compaction (DMC) techniques. In other embodiements, the rotor is comprised of a non-insulated shaft, a magnetic core and a permanent magnet and is formed by first compacting a powdered core material substantially about the non-insulated shaft of relatively incompressible material to form a magnetic core and then compacting a powdered permanent magnet material substantially about the core to form a permanent magnet, with the compaction of the powdered materials occurring by DMC. Other embodiments may be formed by simultaneously compacting a powdered core material and a powdered permanent magnet material about a non-insulated shaft of relatively incompressible material utilizing DMC techniques.

Abstract: A stator is provided for an electrical device (e.g., a motor) comprised of one or more stator segments formed by the compaction of one or more powdered metallic materials. Each stator section has at least one tooth that forms a substantially toroidal path for magnetic flux entering and leaving the stator segment. Each stator segment also has a continuous insulated electrical winding that is associated with the stator segment such that a magnetic field is induced in the stator segment when a current is passed through the continuous insulated electrical winding. The current that is passed through the continuous insulated electrical winding of any one stator segment is not of the same electrical phase as the current that is passed through the winding of any adjacent stator segment.

Abstract: A permanent magnet rotor for a dc brushless motor generally comprised of a non-insulated shaft and and a permanent magnet is formed in one embodiment by compacting a powdered permanent magnet material substantially about a non-insulated shaft of relatively incompressible material utilizing dynamic magnetic compaction (DMC) techniques. In other embodiements, the rotor is comprised of a non-insulated shaft, a magnetic core and a permanent magnet and is formed by first compacting a powdered core material substantially about the non-insulated shaft of relatively incompressible material to form a magnetic core and then compacting a powdered permanent magnet material substantially about the core to form a permanent magnet, with the compaction of the powdered materials occurring by DMC. Other embodiments may be formed by simultaneously compacting a powdered core material and a powdered permanent magnet material about a non-insulated shaft of relatively incompressible material utilizing DMC techniques.