Abstract: Fire-resistant structural composites are comprised of a phenolic resin system, reinforcing fibers and alumina tri-hydrate. The composites may be formed into structural or load-bearing parts, and are particularly suited for applications requiring high strength and a high degree of fire-resistance, such as in the automotive, aircraft, or ship-building industry. Optionally, a siloxane modifier may be added to the resin system to improve the flexibility and impact resistance of the composite.

Abstract: In the embodiments described in the specification, an electric motor has a stator and a rotor and a wrap layer includes composite lamina arrangement containing a liquid barrier with a veil cloth and a chopped strand mat resin layer, a strength element containing a hoop wrap including a polymeric resin layer with continuous fibers extending circumferentially around the rotor and another polymeric resin layer with fibers extending helically, a liquid barrier having a veil cloth and a chopped strand mat resin layer and another strength element including a polymeric resin layer with continuous fibers extending circumferentially around the rotor. The outer surface of the composite lamina arrangement may be corrugated to promote or inhibit flow of liquid through the space between the stator and the rotor.

Abstract: In the embodiments described in the specification, an impeller is manufactured by providing a mold for one angular segment containing one vane of an impeller and corresponding hub and rim portions, injection-molding fiber-reinforced polymer composite resin material into the mold to produce a plurality of substantially identical segments, and assembling the segments into an impeller by bonding corresponding mating end surfaces of the hub and rim portions of the segments. A veil cloth is applied to the outer surface of the rim portion and impregnated with resin material to complete the impeller structure.

Abstract: Encapsulation of a permanent magnet rotor is achieved by applying a glass roving material to spaces in the rotor structure, applying a veil cloth around the outer surface of the rotor, mounting a vacuum bag with vacuum ports around the outer surface of the rotor, removing vent plugs from the end walls of the rotor and screws from an inner ring of the rotor and replacing them with vacuum ports and applying a vacuum to the vacuum ports. After air has been removed from the rotor, an encapsulating resin is applied to some of the ports to introduce resin into the interior of the rotor. After curing of the resin the vacuum bag is removed and the outer surface of the rotor is machined to the desired outer dimension of the rotor.

Abstract: In the embodiments described in the specification, a rim-driven propulsion pod arrangement has a cylindrical housing with a duct providing a flow path for water and a rotor assembly supported from a central shaft and containing a rotating blade row and driven by a rim drive permanent magnet motor recessed in the housing. An array of vanes downstream from the rotating blade row is arranged to straighten the flow of water emerging from the rotating blade row. Radial bearing members on the rotor have a hardness less than that of the shaft on which the rotor is supported and relatively soft protrusions are provided in the space between the rotor and the housing to limit excursion of the rotor. A thrust bearing has wedges arranged to form a water wedge between facing surfaces of the rotor and the rotor support during rotation of the rotor.

Abstract: In the embodiments described in the specification, an impeller is manufactured by providing a mold for one angular segment containing one vane of an impeller and corresponding hub and rim portions, injection-molding fiber-reinforced polymer composite resin material into the mold to produce a plurality of substantially identical segments, and assembling the segments into an impeller by bonding corresponding mating end surfaces of the hub and rim portions of the segments. A veil cloth is applied to the outer surface of the rim portion and impregnated with resin material to complete the impeller structure.

Abstract: In the embodiments described in the specification a deployment arrangement for elongated flexible members such as hoses and cables connected between spaced stationary and rotatable components includes two spaced cylinders of different diameter having walls defining an annular path in the space between the components and a support assembly on each component for supplying a flexible member into the annular space between the walls in a direction substantially perpendicular to the surface of the component facing the annular space. Each of the support assemblies includes a guide which limits the bending angle of the flexible member at the location in which it is introduced into the annular space.

Abstract: Encapsulation of a permanent magnet rotor is achieved by applying a glass roving material to spaces in the rotor structure, applying a veil cloth around the outer surface of the rotor, mounting a vacuum bag with vacuum ports around the outer surface of the rotor, removing vent plugs from the end walls of the rotor and screws from an inner ring of the rotor and replacing them with vacuum ports and applying a vacuum to the vacuum ports. After air has been removed from the rotor, an encapsulating resin is applied to some of the ports to introduce resin into the interior of the rotor. After curing of the resin the vacuum bag is removed and the outer surface of the rotor is machined to the desired outer dimension of the rotor.

Abstract: In the embodiments described in the specification, a rim-driven propulsion pod arrangement has a cylindrical housing with a duct providing a flow path for water and a rotor assembly supported from a central shaft and containing a rotating blade row and driven by a rim drive permanent magnet motor recessed in the housing. An array of vanes downstream from the rotating blade row is arranged to straighten the flow of water emerging from the rotating blade row. Radial bearing members on the rotor have a hardness less than that of the shaft on which the rotor is supported and relatively soft protrusions are provided in the space between the rotor and the housing to limit excursion of the rotor. A thrust bearing has wedges arranged to form a water wedge between facing surfaces of the rotor and the rotor support during rotation of the rotor.

Abstract: In the embodiments described in the specification, an electric motor has a stator and a rotor and a wrap layer includes composite lamina arrangement containing a liquid barrier with a veil cloth and a chopped strand mat resin layer, a strength element containing a hoop wrap including a polymeric resin layer with continuous fibers extending circumferentially around the rotor and another polymeric resin layer with fibers extending helically, a liquid barrier having a veil cloth and a chopped strand mat resin layer and another strength element including a polymeric resin layer with continuous fibers extending circumferentially around the rotor. The outer surface of the composite lamina arrangement may be corrugated to promote or inhibit flow of liquid through the space between the stator and the rotor.

Abstract: In the embodiments described in the specification, permanent magnets are retained on a permanent magnet rotor rim by inverted U-shaped retainers and in one embodiment the outer surfaces of the retainers converge inwardly in the radially outward direction and engage corresponding surfaces of adjacent pole pieces which converge inwardly in the radially outward direction. In another embodiment the U-shaped retainers are affixed to the rotor rim by screws accessible through openings in the radially outer wall of the retainers and a further embodiment each retainer has outwardly projecting flanges which are affixed to the rotor rim by screws.

Abstract: In the embodiments described in the specification, an electric motor has a stator with an inner cylindrical composite can member affixed to the stator housing by screws and the rotor has an outer cylindrical can member affixed to the rotor by screws, each of the composite can members being sealed to the component to which it is affixed by O-rings. In one embodiment ridges are formed in the surface of one of the composite can members facing the space between the stator and the rotor to control the flow of liquid through the space.

Abstract: In the embodiments described in the specification, permanent magnets are retained on a permanent magnet rotor rim by inverted U-shaped retainers and in one embodiment the outer surfaces of the retainers converge inwardly in the radially outward direction and engage corresponding surfaces of adjacent pole pieces which converge inwardly in the radially outward direction. In another embodiment the U-shaped retainers are affixed to the rotor rim by screws accessible through openings in the radially outer wall of the retainers and a further embodiment each retainer has outwardly projecting flanges which are affixed to the rotor rim by screws.

Abstract: In the magnet retention channel arrangement for a high speed rotor described in the specification, a rotor has an array of radially projecting, angularly spaced pole pieces and a magnet retention channel member inserted between each adjacent pair of pole pieces. Each magnet retention channel member is made of nonmagnetic material and has opposed side walls and an integral end wall at one end of the side walls and integral dovetail feet at the opposite ends of side walls. The channels contain permanent magnets and the side walls of uniform thickness with nonmagnetic feet within the core member couple the magnetic flux from the magnets to the pole pieces with substantially no magnetic discontinuities while the presence of the nonmagnetic end wall avoids magnetic shorting.

Abstract: In the magnet retention channel arrangement for a high speed rotor described in the specification, a rotor has an array of radially projecting, angularly spaced pole pieces and a magnet retention channel member inserted between each adjacent pair of pole pieces. Each magnet retention channel member is made of nonmagnetic material and has opposed side walls and an integral end wall at one end of the side walls and integral dovetail feet at the opposite ends of side walls. The channels contain permanent magnets and the side walls of uniform thickness with nonmagnetic feet within the core member couple the magnetic flux from the magnets to the pole pieces with substantially no magnetic discontinuities while the presence of the nonmagnetic end wall avoids magnetic shorting.

Abstract: In the typical embodiments described in the specification, a rolling element bearing arrangement includes an inner raceway with a curved outer surface facing in one lateral direction, an outer raceway with a curved inner surface facing in the opposite lateral direction, an array of rolling elements such as balls engaging the curved surfaces of the inner and outer raceways, a retaining ring in which the array of balls is received, and a retaining ring stabilizer urging the retaining ring in a lateral direction with respect to one of the raceways to inhibit vibration of the components. In addition, a vibration inhibiting outer ring member which may contain a heavy metal or a resilient material, is retained against the outer surface of the outer raceway by a composite wrap which may be a fiber-reinforced organic or inorganic polymer composite made by a dry layup, resin transfer molding, wet filament winding or preimpreganted filament winding technique.

Abstract: In the typical embodiments described in the specification, a rolling element bearing arrangement includes an inner raceway with a curved outer surface facing in one lateral direction, an outer raceway with a curved inner surface facing in the opposite lateral direction, an array of rolling elements such as balls engaging the curved surfaces of the inner and outer raceways, a retaining ring in which the array of balls is received, and a retaining ring stabilizer urging the retaining ring in a lateral direction with respect to one of the raceways to inhibit vibration of the components. In addition, a vibration inhibiting outer ring member which may contain a heavy metal or a resilient material, is retained against the outer surface of the outer raceway by a composite wrap which may be a fiber-reinforced organic or inorganic polymer composite made by a dry layup, resin transfer molding, wet filament winding or preimpreganted filament winding technique.

Abstract: In the rotor arrangement disclosed in the specification a rotor has a central shaft with a surrounding rim to which a circumferential array of pole pieces is mechanically affixed by screws. An array of permanent magnets each mounted between an adjacent pair of pole pieces is radially retained in position by a slot wedge having edges shaped to interlock with the outer side portions of the adjacent pole pieces. The outer surfaces of the pole pieces and slot wedges form a uniform cylindrical outer surface which is covered by an outer wrap of fiber reinforced polymer material to assure that the magnets are retained radially in position.

Abstract: A marine propulsion unit supported from a vessel by a strut contains an electric motor within a housing and a forward propeller driven by the electric motor and having a diameter larger than that of the housing. Hydrodynamic vanes projecting from the surface of the housing counteract tangential flow generated by the forward propeller. An aft section with a pair of counter-rotating blade rows driven by the electric motor is mounted at the rear of the housing and including a shroud surrounding the aft blade rows. The shroud is spaced from the housing so as to receive the boundary layer of liquid passing along the surface of the housing to inhibit cavitation and improve efficiency. Rearward portions of the shroud are movable to form a clamshell causing a reversal of the flow of the liquid passing through the shroud.

Abstract: In the embodiments described in the specification a metal heat transfer cold plate has two sets of parallel coolant passages extending between opposite end surfaces and non-metallic headers made of electrically insulating material are attached to the opposite ends of the metal plate. One of the headers provides an inlet to one set of coolant passages and an outlet from the other set of coolant passages and the other header provides fluid communication between the two sets of coolant passages. The headers are affixed to the cold plate by adhesive or by a snap-in connection having a sealing gasket between each header and the cold plate and the assembled cold plate and headers are insulatively supported by mounting feet attached to the electrically insulating headers.