Abstract: A powdered magnetic material stator core with embedded stator windings and a method for its manufacture. Embedding the windings within a radially compacted powdered magnetic material stator core enables equivalent or better electromagnetic performance in a significantly reduced size. Radial compaction of the powdered magnetic material minimizes the distortion of the stator windings during compaction.

Abstract: Dynamo electric machines and stators for use in such machines are provided. The stators comprise plates configured to be substantially flat and a plurality of spaced apart projections or teeth extending away from the plate and, together with the plate defining a plurality of slots therebetween. The stators comprise masses of metal particles. Using stators made from such metal particles provides enhanced machine efficiency, which is believed to be because of reduced eddy current effects in the stator. Motors including rotors having generally flat arrays of permanent magnetic poles and such stators which are spaced apart from and generally facing the permanent magnetic poles and have a plurality of magnetic windings, and pumps powered by such motors are included within the scope of the present invention.

Abstract: A brush of a rotary electric machine includes a brush element and a pigtail. The brush element includes a high-conduction member extending in the longitudinal direction and a low-conduction member bonded to a side of the high-conduction member. The low-conduction member is a thin layer extending in the longitudinal direction from the contact surface to the middle of the length of the brush element. The wire end is embedded in the high conduction member on the side of the low-conduction member remote from the contact surface.

Abstract: A seal-less pump and electric motor assembly includes a motor rotor fixed to a driving shaft connected to an impeller in the pump assembly. The rotor and impeller are enclosed in a common housing such that the rotor rotates within any fluid being pumped by the impeller. The portion of the housing circumscribing the rotor includes a plurality of axially extending, circumferentially spaced strips of magnetic material penetrating through plastic material of the housing. Each of the strips coincide with corresponding ones of the pole teeth of a motor stator circumscribing the outer portion of the housing such that the strips in the housing act as extensions of the pole teeth. In one embodiment, the strips of magnetic material in the housing are formed by molding powdered iron in a plastic binder material. The strips are then placed in a mold in which the housing is formed by injecting plastic. The plastic binder in the strips melds with the injected plastic to form a continuous housing for enclosing the rotor.

Abstract: A powdered magnetic material stator core with embedded stator windings and a method for its manufacture. Embedding the windings within a radially compacted powdered magnetic material stator core enables equivalent or better electromagnetic performance in a significantly reduced size. Radial compaction of the powdered magnetic material minimizes the distortion of the stator windings during compaction.

Abstract: The carbon commutator of the present invention comprises a plurality of segments having ends which are sliding members on a brush and the other ends to which conductive terminal members are attached, wherein the segments are arranged in a circumferential direction on an insulating boss member and are insulated from each other, carbon layers being formed on the sliding member sides of the segments, metal layers being formed between the carbon layers and the conductive terminal members by sintering a first material of a principal component of the conductive terminal member with a second material which can alloy with the first material.

Abstract: The present invention provides internally damped stators, rotors, and transformers; internally damped cores from which they may be made; and a method of making the aforementioned.

Abstract: An armature core includes a central circular portion and a plurality of equi-spaced extensions extending from the central circular portion outwardly in the radial direction. The extensions and the central circular portions are in the form of an integral configuration and are formed by hot pressing magnetic metal powder particles, each of which is covered by an insulating material.

Abstract: A multipole brushless DC motor stator is formed with a pair of complementary opposable claw pole stator structures in which each of the stator structures comprises a stator base formed of a plurality of stacked sheet metal laminations. A plurality of stator pole members extend from the stator base and are formed by compression molding of a ferromagnetic material. In one form, the ferromagnetic material is molded in situ on the stator base by positioning the stator base in a compression mold having the slots in which a powdered or flaked ferromagnetic material can be positioned and compressed by a die. In another form, the ferromagnetic pole members may be independently compression molded of powdered or flaked ferromagnetic material and then adhesively bonded to the stacked laminations forming the stator base. In either method, the stacked laminations are formed with a plurality of receptacles for receiving one end of each of the stator poles and holding the stator poles to the stator base.

Abstract: Dynamo electric machines and stators for use in such machines are provided. The stators comprise plates configured to be substantially flat and a plurality of spaced apart projections or teeth extending away from the plate and, together with the plate defining a plurality of slots therebetween. The stators comprise masses of metal particles. Using stators made from such metal particles provides enhanced machine efficiency, which is believed to be because of reduced eddy current effects in the stator. Motors including rotors having generally flat arrays of permanent magnetic poles and such stators which are spaced apart from and generally facing the permanent magnetic poles and have a plurality of magnetic windings, and pumps powered by such motors are included within the scope of the present invention.

Abstract: A synchronous generator which is driven by an engine whose rotation variation is large and which can easily incorporate an output voltage stabilization circuit. In this synchronous generator, magnetism shorting paths for a magnetic field produced by the armature coil is formed without changing the armature specifications. Magnetic fluxes produced by currents flowing in the armature coils can easily pass through the magnetism shorting paths, thereby increasing the equivalent inductance value and improving the frequency characteristic of the inductance. This in turn improves the voltage step-up chopper characteristic during generation to stabilize the generated voltage of the synchronous generator driven by, for example, an automobile engine that widely varies in revolution speed.

Abstract: In a stepping motor having a stator provided with an electromagnet and a rotor composed of a hard magnetic alloy, the hard magnetic alloy comprises at least one element T of Fe and Co, at least one element R of rare earth elements and B, has a remanence ratio of at least 0.7, remanent magnetization (Ir) of at least 120 emu/g and coercive force (iHc) of at least 1 kOe and includes a fine crystalline phase having an average crystal grain size of 100 nm or less as a main phase. The hard magnetic alloy is solidified and compacted by making use of a softening phenomenon which arises when the amorphous phase contained in the structure of the hard magnetic alloy is crystallized. A method of manufacturing the hard magnetic alloy used to the stepping motor is also disclosed.

Abstract: Bearing 1 comprises a porous bearing body 1a having a bearing surface 1b disposed to oppose an outer circumferential surface of the rotating shaft 3 via a bearing clearance 4, a lubricating oil or lubricating grease impregnated in the bearing body 1a, and hydrodynamic pressure generating grooves 1c formed on the bearing surface 1b of the bearing body 1a. The rotating shaft 3 is supported, without making contact with the bearing 1, by a hydrodynamic pressure oil film formed in the bearing clearance and the oil is circulated, via openings made in the surface of the bearing body 1a, between the inside of the bearing body 1a and the bearing clearance 4.

Abstract: A motor having an external rotor, or "inside out motor" has a split C arrangement of ferromagnetic members which function as the poles of the electromagnet in the motor. The ferromagnetic members are generally C-shaped and mounted on opposite end caps of the motor. The ferromagnetic members on the opposing end caps are angularly offset from each other. The ferromagnetic members on each end cap are also spaced apart from each other, and receive a portion of the motor windings within them. The motor is constructed for assembly using few or no separate fastening devices to secure the components together. In one embodiment, a bearing core serves as the base on which all parts are assembled.

Abstract: A spindle motor comprises a motor shaft, which is rotatably supported by a motor frame via a bearing and a hub, which is formed integral with the motor shaft for securing a data disk. The hub is made of a powder metallurgical product and is bonded with the motor shaft by sintering.

Abstract: A flat commutator for an electric motor of a vehicle fuel pump. The commutator, is made with a one-piece carbon ring having a flat outer face, a one-piece conductor ring underlying the outer face of and embedded in the carbon ring, and a housing of a plastic insulating material molded on the rear face and the inner and outer edges of the carbon ring and adapted to mount the commutator on a motor armature. A plurality of circumferentially spaced apart grooves extend radially and axially completely through both the carbon ring and the conductor ring to provide a plurality of individual sintered carbon segments each with a separate conductor for electrically connecting the segments with armature coils.

Abstract: This invention provides a method and apparatus for balancing a system including a salient pole rotor machine and an off-balance load. The illustrative embodiment of this invention provides a method and apparatus for balancing the system by positioning a balancing compound between the poles of the rotor of the machine.

Abstract: A motor structure having a stator core including an armature coil wound on stator plates and arranged in parallel on the surface of the motor mounting plate and a bearing mechanism for supporting a rotor rotatably provided at the center of the stator oppositely to the stator wherein the stator core is coupled by an integrally molded form with a housing for holding the bearing mechanism

Abstract: Stepper motor of the type comprising a rotor (1), a stator (2) and a coil (3) consisting of a magnetic core (4) and of a winding (5), in which the stator (2) consists of a soft magnetic alloy of the FeNiCr type, the chemical composition of which includes, by weight: 40%.ltoreq.Ni+Co.ltoreq.60%, 0%.ltoreq.Co.ltoreq.7%, 8%.ltoreq.Cr.ltoreq.13.5%, 8%.ltoreq.Cr+Mn+Si+Mo+Nb+V+W.ltoreq.13.5%, the remainder being iron and impurities resulting from the manufacture. Soft magnetic alloy.

Abstract: A squirrel cage type electric motor rotor assembly includes first and sec end plates of circular configuration, rigid tubes extending from the first plate to the second plate, the tubes being closed at either end thereof to define enclosed chambers therein, and granules of magnetic material disposed in the chambers, the granules being packed therein with a density leaving them readily movable to align with magnetic fields.

Abstract: A flat commutator for an electric motor of a vehicle fuel pump. The commutator is made with a one-piece carbon ring having a flat outer face, a one-piece conductor ring with a base portion embedded in the carbon ring and underlying outer face, and a housing of a plastic insulating material molded on the rear face of the carbon ring and adapted to mount the commutator on a motor armature. A plurality of circumferentially spaced apart grooves extend radially and axially completely through both the carbon ring and the conductor ring to provide a plurality of individual sintered carbon segments each with a separate conductor for electrically connecting the segments with armature coils.

Abstract: A method for fabricating a motor component comprises forming a plurality of substantially parallel electrical current conductors and molding magnetic flux conductive material around at least a portion of each of the plurality of electrical current conductors. In one embodiment the motor component comprises a stator, and the step of forming a plurality of slot liners comprises positioning multi-turn wire coils on a mandrel. In another embodiment, the motor component comprises a rotor, and the step of forming the plurality of substantially parallel electrical current conductors comprises fabricating a rotor cage.

Abstract: An improved, brushless, slot-less DC motor is disclosed which includes a plurality of ring shaped permanent rotor magnets affixed to the motor shaft and magnetized to have contiguous pole faces extending about the circumference thereof. A module plastic housing impregnated with powder metal particles is provided as a magnetic shunt to eliminate prior art ferrite-oxide laminations while assuring concentration of the rotor's magnetic flux into coils positioned in the physical air gap between the rotor and stator housing.

Abstract: A method for fabricating a motor component comprises forming a plurality of substantially parallel electrical current conductors and molding magnetic flux conductive material around at least a portion of each of the plurality of electrical current conductors. In one embodiment the motor component comprises a stator, and the step of forming a plurality of slot liners comprises positioning multi-turn wire coils on a mandrel. In another embodiment, the motor component comprises a rotor, and the step of forming the plurality of substantially parallel electrical current conductors comprises fabricating a rotor cage.

Abstract: A brushless transversal-flux permanent magnet motor has a stator construction that forms a virtual bobbin, so that windings may be simply circumferentially wrapped around the stator, eliminating the need for winding insertion. The stator may be constructed of first and second core structures each having an elongated powdered iron pole piece central portion with end terminations, and integral with a tubular element also of powdered iron. Epoxy, or like non-magnetic material, fills in the volume between the pole piece end terminations to form a disc-shaped structure, the windings wrapping around the tubular elements. A discontinuity is provided on each pole piece and termination to allow start-up. The rotor may be a yoke having permanent magnet rings aligned with the pole pieces, and mounted for rotation by a shaft central of the tubular elements engaging bearings in the tubular elements.

Abstract: A motor, such as a spindle motor, and a method for making such motor, wherein the motor has a stationary part, a rotary part mounted on the stationary part rotatably with respect thereto by a bearing and a magnetic fluid seal mechanism interposed in a radial gap between the stationary part and the rotary part is disclosed. The magnetic fluid seal; mechanism comprises a magnetic ring mounted on the stationary part, a ringlike magnet unit mounted on the rotary part and a magnetic fluid held in a gap between the ringlike magnet unit and the magnetic ring. The magnetic ring is made of a sintered metal made by baking a magnetic metal powder. At last the outer peripheral surface of the magnetic ring is preferably treated with a water-repelling treatment which includes impregnation with resin. All of the surfaces of the magnetic ring are non-cut surfaces.

Abstract: A lightweight high power electromotive device and a method for making the same is provided.

Abstract: An alternating current generator for a motor vehicle includes magnet type field cores, i.e., field cores with claw poles on which permanent magnets are interposed in the spaces between the claw poles, where the generator has a ratio of number of claw poles/outside diameter of the field core that allows generation of a large output current. The alternating current generator includes permanent magnets disposed in spaces between peripherally adjacent claws which reduce the magnetic flux leakage caused by the field coil occurring in the spaces. When a residual magnetic flux density higher than 0.25 tesla is applied in advance in a direction that reduces magnetic flux, a large output current is obtained when the above-noted ratio is in the range of from about 1.6.times.10.sup.-1 to 2.0.times.10.sup.-1 (1/mm).

Abstract: A method of manufacturing an armature for a DC motor comprising the steps of: (a) retaining a plurality of armature conductors pre-positioned in a pre-mold position; (b) placing the armature conductors in a mold; (c) adding to the mold a predetermined quantity of soft-magnetic particles, each soft-magnetic particle coated with a non-magnetic material, wherein said particles surround at least a portion of each of the conductors; (d) applying pressure to the mold to affect a compaction molding of the coated soft magnetic particles into a composite structure, wherein the particles and the non-magnetic material form a composite structure armature core substantially encapsulating the conductors within the armature core.

Abstract: An electric machine includes an exciter part and an induction part disposed adjacent the exciter part. The exciter part and the induction part define an air gap there-between and are movable relative to one another thereby defining a direction of movement. The induction part includes teeth disposed adjacent one another and projecting in a direction toward the air gap. The teeth define grooves therebetween, each of the teeth having a tooth base and a tooth tip adjacent the air gap. In addition, each of a plurality of the teeth further includes a middle portion having two ends and a constant width defined in a direction along the air gap and perpendicular to the direction of movement; and a pair of tooth widening portions, each of the tooth widening portions having a free end and a transition end and being located at one of the two ends of the middle portion at the transition end thereof for forming one of the plurality of the teeth with the middle portion.

Abstract: A permanent magnet rotor for an electric motor has a shaft, a coupler mounted on the shaft, a flux ring fitted to the coupler and located within a ring magnet. The flux ring is a split ring having a nominal outside diameter greater than the inside diameter of the magnet and is keyed to the coupler.

Abstract: The invention relates to a rotor for an electric machine, particularly to a rotor for a hermetic refrigerating compressor. The rotor core contains a number of axial slots, containing the electric conductors of the rotor, which are short-circuited by short-circuiting rings. The rotor has a spindle hole with at least one increased internal diameter for accommodating the bearing neck of the motor. The increased internal diameter of the core results in increased magnetic field strength in the area with increased internal diameter. The invention reduces the magnetic field strength in the area with increased internal diameter by the axial slots having varying profiles in their longitudinal direction.

Abstract: A binded carbon brush includes a brush main portion formed mainly of carbon, and an electric conductor formed by a material, such as a copper powder, having an electric resistivity lower than that of the brush main portion and extending along a main current direction of the brush. In the cross section of the brush perpendicular to the main current direction, the diameter or the vertical and horizontal sizes of the conductor is so set as to be smaller than both the vertical and horizontal sizes of the brush main portion.

Abstract: A rotor especially for use in a high speed electric motor/generator comprises fibre-reinforced plastics material incorporating magnetic filler material, the fibre-reinforced plastics material being arranged as a multi-layered cylindrical portion of the rotor, the magnetic filler material being disposed within and between the layers. The said cylindrical portion may be a hollow tubular portion. The said portion may be enclosed in a non-composite eg, wear resistant, layer.

Abstract: A binded carbon brush includes a brush main portion formed mainly of carbon, and an electric conductor formed by a material, such as a copper powder, having an electric resistivity lower than that of the brush main portion and extending along a main current direction of the brush. In the cross section of the brush perpendicular to the main current direction, the diameter or the vertical and horizontal sizes of the conductor is so set as to be smaller than both the vertical and horizontal sizes of the brush main portion.

Abstract: A rotor for an alternating current generator of the Lundell type. The rotor shaft carries two segments which have interleaved pole teeth. The rotor has a core member and a field coil disposed about the core member. The segments and/or core member are formed of compressed powder iron particles having a particle size in a range of about 10 to 250 microns. In the manufacture of the core and/or segments the iron powder particles are coated with a thermoplastic material and this thermoplastic coated iron particle material is compacted in the molding dies of a press. After compaction to the desired shape, the part is sintered at a temperature of about 2050.degree. F. to burn-off the thermoplastic material that coated the iron particles.

Abstract: A small-sized stepping motor provided with can-type stator yokes and one flat-type stator yoke, all of which are injection molded of a composite powder (i.e., a mixture of a metal powder of a soft magnetic material, a powder of a thermoplastic synthetic resin). The injection molded stator yokes have a considerably large specific electrical resistance, and the stepping motor is free from various disadvantages resulting from a small specific electric resistance.

Abstract: An electromagnetic transducer is disclosed that is lightweight and has a high power to weight ratio, with the transducer being capable of operation as an efficient motor, alternator or generator, and being particularly useful, for example, in connection with self-propelled vehicle applications such as passenger cars. The electromagnetic transducer can utilize a shell construction, which enhances heat removal, and includes a magnetic-flux producing assembly, having a plurality of spaced magnetic elements, and an armature assembly formed by a winding arrangement of dispersed conductive elements which are separated by flux carrying elements which, to the extent that such flux carrying elements are electrically conductive, are dispersed in one, two or three dimensions to thus be dispersed-phase flux carrying elements. The armature conductors and flux carrying elements are dispersed to minimize creation of opposing induced current, or eddy currents, depending on the effect produced on transducer operation.

Abstract: A rotor for rotary electrical machinery comprising a permanent-magnet member made of a mixture having ferromagnetic material powder and a binder resin for chief ingredients, and a shaft, in which a recess whose projected contour on a plane orthogonally intersecting the axial line of the permanent-magnet member is of a non-circular shape is provided at least an end face of the permanent-magnet member, and a shaft is press-fit into a metallic bush fitted to the recess, thereby ensuring high coaxiality tolerance between the permanent-magnet member and the shaft, easy assembly and low manufacturing cost.

Abstract: Permanent magnets are mounted onto a punch, wherein the punch and associated magnets are fitted into a die which is then filled with a mixture of metal powder and thermosetting resin, in order to obtain, in a single operation, a stator having the permanent magnets embedded therein and being, integral with the body of a reduction unit connected to the motor.

Abstract: A brush device, comprising a brush holder and a brush assembly, for providing electrical contact with a moving part while suppressing electrical noise generated during the interaction of the brush device with the moving part. The brush holder includes a housing adapted to receive a brush assembly within the housing, and noise suppression arrangement, mounted on the housing and electrically connected to a brush assembly, for suppressing electrical noise generated during the interaction of the brush assembly and the moving part by providing an inductive impedance in the electrical path of the brush assembly. The brush holder may further include a connector cap, electrically connected to the noise suppression arrangement, adapted to provide a mating connection between the noise suppression arrangement and an external connector. The brush assembly is positioned within the housing such that sliding electrical contact is made with the moving part.

Abstract: Energy efficiency of electric motors and transformer, inductor and ballast apparatus is increased through use of amorphous ferromagnetic materials and thin section electrical steels by methods using folding of lamination stock, forming of lamination stock after folding or punching, and stacking to form substantially solid flux-conducting structures. Such apparatus may employ multiple ferromagnetic materials to conduct major portions of the magnetic flux in the apparatus magnetic circuit. Apparatus is also described in which magnetic and mechanical support functions reside in differing ferromagnetic or structural plastic materials in composite structures.

Abstract: An improved disk-type machine having a plurality of alternating stator and/or rotor sections is disclosed. The stator of the machine has microlaminated stator teeth molded from cut steel particles, mounted on a large disk of composite fiber material which is the main structural component of each stator section. The stator teeth are preferably molded in place during disk manufacture. The stator is designed to operate in a machine having an even number of axial air gaps, but has only a single winding for each stator. One layer of the winding is located on each side of the central supporting disk and the ends of the windings are connected through connectors molded into or mounted on the disk. Multiturn coils may be employed by making a plurality of these connections for each coil. The interior rotor sections of the machine are likewise constructed on supporting rotor disks of composite material, and have pole pieces molded into place during disk manufacture which are wound on both sides of the supporting disk.

Abstract: A field magnet for miniature motors of a type having a stator comprising a field magnet fixedly fitted to a motor housing, an end plate fitted to an open end of the motor housing; and a rotor comprising a rotor winding wound on a rotor core; electric current being fed to the rotor winding via a commutator making sliding contact with current feeding brushes that are held by brush holders fixedly fitted to the end plate; in which cogging during motor rotation is reduced to make motor rotation smooth by forming a magnet that has at the magnetic poles thereof higher maximum magnetic energy product than any other regions.

Abstract: Lower coils (5b) and upper coils (5a) are inserted to slots (12) of a cylindrical armature core (4). The upper coils are used as crossover lines (102a) at the side of commutator (10) and form commutator segments. The crossover lines are approximately deviated by a pole pitch (yf) at the commutator and inserted to other slots as lower coils. The lower coils are used again as crossover lines and deviated approximately by the pole pitch at the opposite side of the commutator so as to be inserted again to the slots as the lower coils. An insulating resin (11) are forced to push into inner peripheral sides of the armature core, and the crossover lines forming a squirrel cage type shape and extending cylindrically from the core.

Abstract: A frame and permanent magnet assembly for a dynamoelectric machine where the frame carries a plurality of permanent magnets. The frame is formed of iron powder particles that are bound together by a thermoplastic material. In the manufacture of the assembly, iron powder particles that are coated with a thermoplastic material are molded to the permanent magnets. The permanent magnets have surfaces that are interlocked to the material of the frame thereby eliminating the need for mechanical fasteners or an adhesive to secure the permanent magnets to a frame.

Abstract: A dynamoelectric machine having a stator which is composed of a stator core formed of a mold resin containing silicon steel powder, and a magnetic field generating coil having coil turns arranged to generate sine-wave magnetic fields and embedded in the mold resin of the stator core. The coil ends of the coil turns of the magnetic field generating coil are bent so as to extend along both side surfaces of the stator core. Disclosed also is a method of producing this stator.

Abstract: An electric rotary machine such as a motor has a rotor having a plurality of poles, a stator having a plurality of poles confronting the poles of the rotor in a radial direction, and a casing, for the rotor, having a cylindrical portion which extends in an axial direction. A permanent magnet composed of a mixed material of magnetic powder and a binder being a thermosetting resin constitutes the poles of the rotor. The permanent magnet, which is ring-shaped, is mounted in the casing along an inner circumference of the cylindrical portion of the casing in a circumferential direction. A yoke member is mounted around an outer circumference of the cylindrical portion of the casing, and a plurality of openings penetrate the cylindrical portion and the yoke member at the same time. The permanent magnet has a plurality of projections monolithically formed on its outer circumference. The projections are fitted in the respective openings in the yoke member and cylindrical portion.

Abstract: An electromagnetic transducer is disclosed that is lightweight and has a high power to weight ratio, with the transducer being capable of operation as an efficient motor, alternator or generator, and being particularly useful, for example, in connection with self-propelled vehicle applications such as passenger cars. The electromagnetic transducer can utilize a shell construction, which enhances heat removal, and includes a magnetic-flux producing assembly, having a plurality of spaced magnetic elements, and an armature assembly formed by a winding arrangement of dispersed conductive elements which are separated by flux carrying elements which, to the extent that such flux carrying elements are electrically conductive, are dispersed in one, two, or three dimensions to thus be dispersed-phase flux carrying elements. The armature conductors and flux carrying elements are dispersed to minimize creation of opposing induced currents, or eddy currents, depending on the effect produced on transducer operation.

Abstract: In a self-starting two-pole single-phase synchronous motor with a permanent magnetic rotor, which as a result of diametrical magnetization comprises two opposite pole faces on its circumference, the rotor is made of a plastics-bonded anisotropic magnetic material, the two opposite pole faces each being limited to an angular range of the rotor circumference starting from the rotor axis, which is smaller than 90.degree..