Laminate for rotor of electric machine

Abstract

A rotor of an electric machine is provided. The rotor includes a plurality of laminates arranged in an axial direction, the plurality of laminates including a first laminate having: a body formed of a first material, the first material being a ferromagnetic material; and a structural element integrally formed from a second material with the body, the second material being a non-ferromagnetic material.

Description

[0001] Priority information

[0002] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 516,155 filed on July 28, 2023 and U.S. Provisional Patent Application Serial No. 63 / 517,718 filed on August 4, 2023, the disclosures of which are incorporated herein by reference. Technical Field

[0003] The present disclosure generally relates to laminates for rotors of electric machines and methods of making the same. Background Art

[0004] Electrical machines (i.e. motors and generators) with high power density and high efficiency have long been required for various applications, especially energy production applications. The current trend is to increase the speed to increase the power density of the machine, thereby reducing its mass and cost.

[0005] For example, the power output of a motor can be increased by increasing machine size, improving thermal management, increasing rotor speed, or increasing magnetic utilization. However, material selection and design criteria must balance electromagnetic and mechanical performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] A full and enabling disclosure of the present disclosure, including the best mode thereof, to one skilled in the art is set forth in the specification with reference to the accompanying drawings, in which:

[0007] Figure 1 is a side cross-sectional view of a portion of an electric machine according to an exemplary aspect of the present disclosure.

[0008] Figure 2 is a perspective view of a body component according to an exemplary aspect of the present disclosure.

[0009] Figure 3 According to an exemplary aspect of the present disclosure Figure 2 A stereoscopic image of a sliced ​​section of the main components.

[0010] Figure 4 According to an exemplary aspect of the present disclosure, Figure 3 A three-dimensional view of a soft magnetic thin film laminate with the main body components being sliced.

[0011] Figure 5 is a perspective view of a plurality of thin film laminates as part of an electric machine according to an exemplary aspect of the present disclosure.

[0012] Figure 6 is a schematic diagram of a laminate according to an exemplary embodiment of the present invention.

[0013] Figure 7is a schematic diagram of a laminate according to another exemplary embodiment of the present invention.

[0014] Figure 8 is a schematic diagram of a laminate according to yet another exemplary embodiment of the present invention.

[0015] Fig. 9 is a schematic diagram of a laminate according to yet another exemplary embodiment of the present invention.

[0016] Fig.10 is a schematic diagram of a laminate according to yet another exemplary embodiment of the present invention.

[0017] Fig.11 is a schematic diagram of a laminate according to yet another exemplary embodiment of the present invention.

[0018] Fig.12 is a schematic diagram of a laminate according to yet another exemplary embodiment of the present invention.

[0019] Fig.13 is a schematic diagram of a laminate according to yet another exemplary embodiment of the present invention.

[0020] Fig.14 is a schematic diagram of a laminate according to yet another exemplary embodiment of the present invention.

[0021] Fig.15 is a schematic diagram of a laminate according to yet another exemplary embodiment of the present invention.

[0022] Fig.16 A flow chart showing an exemplary method of making a laminate according to an exemplary aspect of the present disclosure is provided.

[0023] Fig.17 is a perspective view of a rotor of a motor according to an embodiment of the present specification.

[0024] Fig.18A , Fig.18B and Fig. 18C is a perspective view of a rotor according to some embodiments of the present specification. DETAILED DESCRIPTION

[0025] Reference will now be made in detail to the present embodiments of the present disclosure, one or more examples of which are shown in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. The same or similar designations in the drawings and description have been used to refer to the same or similar parts of the present disclosure.

[0026] As used herein, the word "exemplary" means "serving as an example, instance, or illustration." Any implementation described herein as "exemplary" is not necessarily to be construed as preferred or better than other implementations. In addition, unless expressly stated otherwise, all embodiments described herein should be considered exemplary.

[0027] The singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0028] For example, in the context of “at least one of A, B, and C,” the term “at least one” means only A, only B, only C, or any combination of A, B, and C.

[0029] The term “turbomachine” refers to a machine that includes one or more compressors, a heat generating section (eg, a combustion section), and one or more turbines that together produce a torque output.

[0030] The term "gas turbine engine" refers to an engine having a turbine as all or part of its power source. Example gas turbine engines include turbofan engines, turboprop engines, turbojets, turboshaft engines, etc., as well as hybrid-electric versions of one or more of these engines.

[0031] As used herein, the terms "axial" and "axially" refer to directions and orientations extending substantially parallel to a centerline of a component (e.g., a motor). Additionally, the terms "radial" and "radially" refer to directions and orientations extending substantially perpendicular to the centerline. Additionally, as used herein, the terms "circumferential" and "circumferentially" refer to directions and orientations extending in an arc around the centerline.

[0032] The term "electric machine" generally refers to a machine having a stator and a rotor that is rotatable relative to the stator. In addition, the electric machine can be configured in any suitable manner to convert mechanical energy (e.g., from a turbine, such as a gas turbine engine) into electrical energy, or to convert electrical energy into mechanical energy. For example, the electric machine can be configured as a synchronous reluctance motor; a permanent magnet motor (e.g., an interior permanent magnet motor) and / or a spoke permanent magnet motor; or a closed rotor slot induction motor. In this manner, the electric machine can be operated to generate or utilize alternating current (AC) power or direct current (DC) power. It should also be understood that the stator, the rotor, or both can generally include one or more of a plurality of coils or windings arranged in any suitable number of phases, one or more permanent magnets, one or more electromagnets, and the like.

[0033] Chemical elements are discussed in this disclosure using their common chemical abbreviations, such as those commonly seen in the periodic table. For example, hydrogen is represented by its common chemical abbreviation H; helium is represented by its common chemical abbreviation He; and so on.

[0034] The terms “coupled,” “fixed,” “attached to,” and the like refer to both direct coupling, fixing, or attachment as well as indirect coupling, fixing, or attachment through one or more intermediate components or features, unless otherwise specified herein.

[0035] As used herein, the terms “first,” “second,” and “third” may be used interchangeably to distinguish one component from another, and are not intended to indicate the position or importance of each component.

[0036] The term "adjacent" as used herein with respect to two walls and / or surfaces means that the two walls and / or surfaces are in contact with each other, or that the two walls and / or surfaces are separated only by one or more non-structural layers, and that the two walls and / or surfaces are in a series contacting relationship with the one or more non-structural layers (i.e., a first wall / surface contacts the one or more non-structural layers, and the one or more non-structural layers contacts the second wall / surface).

[0037] As described herein, the subject matter currently disclosed may involve the use of an additive manufacturing machine or system. As used herein, the term "additive manufacturing" generally refers to a manufacturing technique for manufacturing parts in a layer-by-layer manner. An exemplary additive manufacturing machine may be configured to utilize any suitable additive manufacturing technique. An additive manufacturing machine may utilize additive manufacturing techniques including powder bed fusion (PBF) techniques, such as laser powder bed fusion (LPBF) techniques, which are sometimes also referred to as direct metal laser melting (DMLM), selective laser melting (SLM) techniques, directional metal laser sintering (DMLS) techniques, or selective laser sintering (SLS) techniques. In an exemplary PBF technique, thin layers of powdered material are sequentially applied to a build plane and then selectively melted or fused together in a layer-by-layer manner to form one or more three-dimensional objects. Additively manufactured objects are typically integral in nature and may have various integral sub-components.

[0038] Additionally or alternatively, suitable additive manufacturing techniques may include, for example, fused deposition modeling (FDM) technology, directed energy deposition (DED) technology, laser engineered net shaping (LENS) technology, laser net shaping manufacturing (LNSM) technology, direct metal deposition (DMD) technology, digital light processing (DLP) technology, binder jetting, and other additive manufacturing techniques that utilize an energy beam or other energy source to solidify additive manufacturing materials (e.g., powder materials).

[0039] For example, in the DED process, an energy source can be used to form a molten pool on a substrate. At the same time, a powder or filament material to be deposited can be fed into the molten pool, where the material melts and fuses with the substrate. The energy source and the material feed nozzle move relative to the substrate, usually along a pre-programmed path, to form the desired shape. The advantages of the DED process are the ability to create parts relatively quickly and the ability to use multiple materials in a single print.

[0040] Additive manufacturing techniques can generally be described as manufacturing an object by building the object point by point, line by line, or layer by layer, usually in a vertical direction. Other manufacturing methods are contemplated and are within the scope of the present disclosure. For example, although the discussion herein relates to adding material to form successive layers, the subject matter of the present disclosure can be practiced using any additive manufacturing technique or other manufacturing technique, including a layer additive process, a layer subtractive process, or a hybrid process.

[0041] The additive manufacturing processes described herein can be used to form parts using any suitable material. For example, the material can be a metal, a ceramic, a polymer, an epoxy resin, a photopolymer resin, a plastic, or any other suitable material, and can be a solid, a powder, a sheet material, a wire, or any other suitable form, or a combination thereof. Additionally or alternatively, exemplary materials may include metals, ceramics, or adhesives, and combinations thereof. Exemplary ceramics may include ultra-high temperature ceramics and / or precursors to ultra-high temperature ceramics, such as polymer precursors. Each continuous layer may be, for example, between about 10 μm and 200 μm, but the thickness may be determined based on any number of parameters and may be of any suitable size.

[0042] As used herein, the term "build plane" refers to a plane defined by the surface of a powder material impacted by an energy beam to selectively irradiate and consolidate the powder material during an additive manufacturing process. Typically, the surface of a powder bed defines the build plane. During irradiation of layers of the powder bed, previously irradiated portions of each layer may define a portion of the build plane. Prior to distributing the powder material on a build module, a build plate supporting the powder bed typically defines the build plane.

[0043] As used herein, the term "consolidation" or "consolidated" refers to the solidification of the powder material as a result of irradiating the powder material, including by melting, fusion, sintering, and the like.

[0044] The present disclosure relates generally to laminates, such as laminates for use in electric machines. In electric machine topologies, there may be a trade-off between electromagnetic performance and mechanical performance. For example, in an interior permanent magnet (IPM) machine, the trade-off may manifest as the size of the bridge and center post that hold the laminates together. Structurally, it is desirable to include a larger bridge and center post in order to maintain mechanical integrity at high rotational speeds. However, electromagnetically, the bridge and center post may retain magnetic flux in the rotor, which may result in flux leakage. However, reducing the size of the bridge and post may negatively impact the structural requirements to support internal stresses to operate at the desired speed and torque.

[0045] Magnetic utilization can also be improved by additionally or alternatively using low permeability materials as bridges and center posts. For example, one approach could be to create an integral laminate with different magnetic states at desired locations, such as using gas nitridation and local heating to effect local phase transformation and magnetic state change. However, this approach may have a specific alloy composition window and have limitations on magnetic and mechanical properties.

[0046] The disclosure herein provides a multi-material laminate for a motor to solve the above-mentioned structural and electromagnetic problems, and also provides a new manufacturing method for manufacturing the multi-material laminate for a motor.

[0047] In at least some embodiments, a multi-material laminate can be formed into a bulk near-net-shape component having a variety or multiple materials with tailored magnetic and / or mechanical properties. Depending on the material composition, the component can be manufactured by various investment casting techniques, additive manufacturing techniques, or a hybrid combination of investment casting and additive manufacturing techniques. The component can then be sliced ​​into thin laminates, such as by electrochemical machining in a non-limiting example. Due to the near-net-shape original component, the resulting laminate may inherently have the desired geometry and can subsequently be assembled into at least a portion of an electric machine, such as a rotor.

[0048] For example, in certain exemplary aspects of the present disclosure, a rotor of an electric machine may be manufactured. The rotor may define an axial direction and a radial direction, and may include a plurality of laminates arranged along the axial direction. The plurality of laminates may include a first laminate having a body formed of a first material. The first material may be a ferromagnetic material. The first laminate may also include a structural element formed integrally with the body by a second material. The second material may be a non-ferromagnetic material. For example, the body may define a flux barrier region, and the structural element may be a bridge located at the end of the flux barrier region, or a column extending through the interior of the flux barrier region.

[0049] Referring now to the drawings, wherein like numerals refer to like elements throughout, Figure 1An example of a portion of an electric machine 100 is shown. The electric machine 100 can be a synchronous reluctance or interior permanent magnet electric machine. The electric machine 100 includes a stator 102 having a distributed or concentrated conductive winding 104 through which current is conducted to operate the electric machine 100. The electric machine 100 also includes a rotor 106, which is formed by a laminated stack of conductive sheets that are insulated from each other and clamped together. In some embodiments, the electric machine 100 can be used as an electric motor to operate to propel a vehicle. For example, the rotor 106 can be rotated by a current in the conductive winding 104 of the stator 102, which rotates a shaft connected to the rotor 106. The shaft can be connected to turbine rotor blades, axles, wheels, etc. to help propel a vehicle such as an aircraft, a land vehicle (e.g., a car, a rail vehicle, a mining vehicle, etc.) or a ship.

[0050] The rotor 106 may be formed at least in part of a ferromagnetic material that allows magnetic flux to flow through the rotor 106. The rotor 106 may include one or more features that define a flux carrier portion 108 of the rotor 106 and flux barriers 110 of the rotor 106. The flux barriers 110 may be gaps or removed portions in the rotor 106, such as air gaps in the rotor 106. Permanent magnets 112 may be placed within these flux barriers 110, as shown in the illustrated embodiment.

[0051] Alternatively, there may be no permanent magnets 112 (not shown) located in the flux barrier 110 (in which case it would be a synchronous reluctance machine).

[0052] Flux carrier portions 108 represent the sections of rotor 106 that remain after flux barriers 110 are cut from, removed from, or otherwise formed in rotor 106 .

[0053] Adjacent flux carrier segments 108 may be connected in a radial direction R (e.g., a direction extending radially from a central axis or rotational axis 116 of the rotor 106) by elongated posts 114. Ends of the flux carrier segments 108 may be connected in a circumferential direction C (a direction circumferentially surrounding the rotational axis 116 of the rotor 106) by bridges 118. As will be discussed in more detail below, the flux carrier segments 108, the bridges 118, or both may be formed of a different material than the body segments shown.

[0054] In operation, a varying current is conducted through the conductive windings 104 to rotate the rotor 106 relative to the stator 102. The current generates magnetic flux in the rotor 106. The flux carrier portions 108 guide and carry the magnetic flux in the rotor 106, while the flux barrier portions 110 block or obstruct the flow of magnetic flux in the rotor 106. These flux carrier portions 108 create a larger reluctance path in the rotor 106 along a first axis 120 (e.g., the quadrature axis or "q" axis of the rotor 106) and a smaller reluctance path in the rotor 106 along a different second axis 122 (e.g., the direct axis or "d" axis of the rotor 106). The difference in reluctance along the first axis 120 and the second axis 122 results in a total reluctance torque. The difference in reluctance can be caused by the shape and size of the flux carrier portions 108 and the flux barrier portions 110.

[0055] refer to Figure 2 , shows a body component 200 for making a thin laminate. The body component 200 can be a near net shape component. As used herein, near net shape refers to a component whose shape is substantially the same (e.g., having the same dimensions or within 5%) as the dimensions of an end-use component to be used in an electric machine in any given direction. As a non-limiting example, Figure 2 As shown, the body component 200 may be shaped as a rotor of a motor. That is, the body component 200 may include an annular body 201 surrounding a hollow core 202. The hollow core 202 may extend in an axial direction A, and the annular body 201 may extend away from the hollow core 202 in a radial direction R perpendicular to the axial direction A. In the example shown, the annular body 201 is a square annular body, but this is not necessarily the case.

[0056] The body component 200 may further include a plurality of flux barrier gaps 210. The flux barrier gaps 210 may be distributed around a central axis 205 extending in the axial direction A. Each flux barrier gap 210 may extend through the body component 200 in the axial direction A from a first end 207 to a second end 208 opposite the first end. Figure 1 As shown in the rotor 106 shown in FIG. 1 and as described above, one or more flux barrier gaps 210 may be configured to ultimately receive one or more permanent magnets ( Figure 1 112 in the above).

[0057] The main body 200, including the flux barrier gap 210, can be presented in various topological structures. Figure 2 As shown, four groups of flux barrier gaps 210 can be symmetrically distributed around the central axis 205 of the main body. In one or more of these flux barrier gaps 210, two adjacent flux barrier gaps 210 can be arranged in a V-shaped orientation. That is, the first flux barrier gap 211 and the second flux barrier gap 212 can be tilted downward and toward each other to form a V-shaped orientation.

[0058] The absence of material at the flux barrier gap 210 may result in one or more high stress locations 230, 231 in the body component 200. For example, when two adjacent flux barrier gaps 210 are arranged in a V-shaped orientation to define a column 220, the material of the body component 200 between the two flux barrier gaps 210 may define a first high stress location 230 due to increased mechanical stress at the isolation material forming the center column 220. Similarly, a second high stress location 231 may exist directly adjacent to the flux barrier gap 210, such as at a bridge 221 of the flux barrier gap 210, or at an outer corner or edge of the flux barrier gap 210 farthest from the center axis 205. As disclosed herein, the material of these high stress locations 230, 231 can be tailored to provide low permeability and low magnetic saturation, as well as high mechanical strength.

[0059] In some embodiments, the body component 200 includes a plurality of different materials (e.g., different alloys) such that it is a multi-material body component. For example, the body component 200 may include a ferromagnetic material and a non-ferromagnetic material, as will be discussed in more detail below. Different materials may be used at different locations of the body component 200. For example, a material having a higher tensile strength and a lower magnetic permeability may be used at one or more high stress locations 230, 231 of the body component 200 (e.g., at the center column 220, or at the bridge 221 between or near the flux barrier gap 210), while a majority or remainder of the body component 200 may include a ferromagnetic material.

[0060] A variety of potential techniques may be used to produce body component 200. In some embodiments, multi-material body component 200 may be formed using, for example, additive manufacturing, investment casting, or a hybrid combination of additive manufacturing and investment casting. For example, in some embodiments, multi-material body component 200 may be produced by LPBF, DED, or binder jetting additive manufacturing techniques.

[0061] In some embodiments, the body component 200 can be heat treated. For example, the body component 200 can be heat treated at one or more temperatures prior to subsequent processing steps, such as heat treating the body component 200 before cutting it into a plurality of laminates. Heat treating the body component 200 can improve the mechanical or magnetic properties of the body component 200, such as by relieving residual stresses in the body component 200 (e.g., from additive manufacturing), or otherwise changing the strength, hardness, or other mechanical or magnetic properties of the body component 200.

[0062] It is worth noting that in some embodiments, the main body component 200 can be made into a near net shape of a final component (e.g., a part of an electric machine) by casting, additive manufacturing, or other manufacturing techniques. However, in other embodiments, the main body component 200 can be further processed into a near net shape of a desired component, such as when the original product of the main body component is different from the final desired shape. Processing can include, for example, electrical discharge machining, mechanical grinding, or lathe machining.

[0063] refer to Figure 3 , showing Figure 2 The main body component 200 in the embodiment is sliced ​​to produce a plurality of laminates 260. That is, after the main body component 200 is produced, it can be sliced ​​into a plurality of laminates 260. Due to the near net shape of the main body component 200, the resulting laminates 260 can inherently have the geometry required for the motor.

[0064] like Figure 3 As shown, the body component 200 can be sliced ​​along a radial direction R perpendicular to the axial direction A. For example, a first laminate 261 can be sliced ​​from the first end 207 of the body component 200, and then a second laminate 262, a third laminate 263, and so on. Therefore, the body component 200 can be easily sliced ​​into a plurality of laminates 260 with customized mechanical properties using a coordinated material selection.

[0065] The thickness of the plurality of laminates 260 in the axial direction can be adjusted according to the needs of the parts of the final assembled motor. The appropriate laminate thickness can be determined by the motor performance requirements and balanced by eddy current loss and stacking factor. For example, the thickness of each laminate 260 can be less than or equal to 0.75 millimeters (mm), or less than or equal to 0.65 mm, or less than or equal to 0.5 mm. In some embodiments, the thickness of each laminate 260 can be 0.1 mm to 0.75 mm, or 0.15 mm to 0.5 mm. In some embodiments, each of the plurality of laminates 260 can have the same thickness. However, in some embodiments, the thickness of the laminates 260 can be different from each other, so that some laminates 260 can be thicker than other laminates.

[0066] In some embodiments, the body component 200 may be sliced ​​via electrochemical machining (ECM). With ECM, the body component 200 may be sliced ​​at multiple locations using a wire to produce multiple laminates 260. Notably, due to the chemical nature of the ECM, little to no heat input may occur during machining of the laminates 260. Due to the lack of heat input during machining, the microstructure and material properties of the body component 200 may remain intact even when sliced ​​into multiple laminates 260. In addition, some body components may contain residual stresses and are susceptible to warping when heat is applied during slicing. However, with ECM, warping may be avoided because no heat is applied during slicing.

[0067] However, in other exemplary embodiments, alternative cutting methods may be utilized, such as electrical discharge machining (EDM), which may or may not be combined with additional machining steps to achieve the final product.

[0068] Although Figure 3 and related descriptions relate to slicing a body component 200 to produce a plurality of laminates 260, but alternative or additional methods may also be employed or avoided. For example, in some embodiments, one or more laminates may be produced from the body component without rolling. As used herein, without rolling refers to producing the component without using conventional rolling techniques (e.g., hot rolling or cold rolling). For example, by slicing a body component (e.g., a near-net shape body component) via ECM, the resulting plurality of laminates may define a desired shape, thereby avoiding the potential need for rolling techniques.

[0069] Reference now Figure 4 , showing that from Figure 2 and Figure 3 The first laminate 261 cut out of the main body component 200 shown in FIG. As shown, the first laminate 261 can have a desired morphology after slicing without the need for additional processing steps, thereby simplifying the overall manufacturing.

[0070] In some embodiments, the first laminate 261 may be subjected to one or more processing steps. For example, depending on the material, the surface 270 of the first laminate 261 may be treated to provide protection, insulation, or other desired properties. In some embodiments, the surface 270 of the first laminate 261 may be coated with a resistive coating at one or more locations. For example, high silicon steel (e.g., Fe-6.5Si) may be coated with a C5 coating to provide an insulating layer. In some embodiments, the surface 270 of the first laminate 261 may be oxidized at one or more locations. Depending on the material of the first laminate 261, oxidation of the surface may naturally produce a resistive layer, so no supplemental insulating coating is required. For example, surface oxidation of an iron-cobalt alloy may provide a resistive layer without the need for a supplemental coating.

[0071] refer to Figure 5 , showing a portion of an electric machine 300 utilizing a plurality of laminates 320. The laminates 320 can be produced using the methods and processes disclosed herein and have a variety of potential morphologies. That is, after the plurality of laminates 320 are cut out from the main body component, they can be assembled into a plurality of stacked layers for the electric machine 300. For example, as Figure 5 As shown, multiple laminates 320 can be stacked concentrically onto shaft 310. In some embodiments, each of the multiple laminates 320 can be separated by gaps 322. Gap 322 can be electrically insulating, such as by filling an insulating material to separate each of the multiple laminates. In some embodiments, multiple laminates 320 can be stacked and bonded, such as chemically bonded via epoxy or other bonding materials.

[0072] Although Figure 5 The laminates 320 are shown forming a rotor of the electric machine 300, but the laminates 320 may alternatively form one or more other components of the electric machine 300. For example, in some embodiments, the laminates 320 may be combined to form a stator (not shown) of the electric machine 300.

[0073] Reference now Figure 6 , a laminate 400 according to an exemplary embodiment of the present disclosure is provided. Figure 6 The laminate 400 may be the first laminate of a plurality of laminates that form a portion of an electric machine, such as a rotor of the electric machine (see, e.g. Figures 1 to 5 ). Specifically, and as will be understood from the discussion below, for Figure 6 In an embodiment, laminate 400 may be used to form a rotor of an interior permanent magnet motor.

[0074] The laminate 400 defines an axial direction A, a radial direction R, and a circumferential direction C, and generally includes a body 402 formed of a first material and a structural element formed integrally with the body 402 by a second material. As used herein, the term "integrally formed" when used to describe two materials means that the two materials are formed together, i.e., not formed separately and then assembled, such that there is no seam or joint between the two materials. Two or more materials formed according to one or more exemplary methods described herein fall within the scope of the term "integrally formed" in the present disclosure.

[0075] The first material is a ferromagnetic material. As used herein, the term "ferromagnetic" refers to a material having the ability to be magnetized and attracted by a magnet, such as a material having a relative magnetic permeability greater than 1 before saturation, and generally greater than or equal to 100 and less than or equal to 10,000. In this manner, the first material can be iron, nickel, cobalt, and / or alloys thereof. For example, in certain exemplary embodiments, the first material can be an iron-cobalt alloy (FeCo). In this manner, it will be appreciated that the first material can define a relatively high magnetic flux density, such as at least 2 Tesla (T), such as at least 2.25 T, such as up to 3.5 T.

[0076] The second material is a non-ferromagnetic material. As used herein, the term "non-ferromagnetic material" refers to a material that does not exhibit ferromagnetism, such as a material having a relative magnetic permeability of 1 or about 1 (e.g., less than 10), such as a material with high magnetic reluctance. The second material forming the structural element can be selected to include more ideal mechanical properties than the first material in order to provide structural benefits to the laminate 400. For example, it should be understood that the first material can define a first yield strength and the second material can define a second yield strength. The second yield strength can be greater than the first yield strength in order to provide the desired structural rigidity for the laminate 400.

[0077] As used herein, the terms "greater than" and "less than" used when comparing two yield strengths refer to comparing the yield strengths of two materials at the same temperature and the same environmental conditions (e.g., pressure). In certain exemplary embodiments, "greater than" may mean at least 10% greater and at most 1,000% greater, such as at least 20% greater and at most 200% greater (the smaller value is in the denominator). In addition, in certain exemplary embodiments, "less than" may mean at least 5% less and at most 90% greater, such as at least 10% greater and at most 75% greater (the larger value is in the denominator).

[0078] For example, in one exemplary embodiment, the second yield strength can be greater than 100 kilopounds per square inch (ksi), such as greater than 125 ksi, such as greater than 150 ksi, such as up to 600 ksi. For example, the second material can be a nickel-chromium alloy, such as Inconel TM 718. The first material may be a ferrous material, such as iron-cobalt.

[0079] In particular, still refer to Figure 6 It should be understood that the body 402 defines a flux barrier region 404, a flux carrier portion 406, and a hollow core 405. The structural element may be a bridge 408 positioned at a first end 410 of the flux barrier region 404, a bridge 408 positioned at a second end 412 of the flux barrier region 404, or a column 414 extending through an interior 416 of the flux barrier region 404. In particular, for Figure 6In an embodiment of the present invention, the structural element is a first structural element of a plurality of structural elements. Each of the plurality of structural elements is formed of a second material and is integrally formed with the body 402 of the laminate 400.

[0080] More specifically, the plurality of structural elements include a first bridge 408A positioned at a first end 410 of flux barrier region 404 , a second bridge 408B positioned at a second end 412 of flux barrier region 404 , and a post 414 extending through an interior 416 of flux barrier region 404 between the first and second ends 412 .

[0081] More specifically, the flux barrier region 404 is a first flux barrier region 404A, and the laminate 400 defines a plurality of flux barrier regions 404. Each of the plurality of flux barrier regions 404 defined by the body 402 of the laminate 400 includes a first bridge 408A and a second bridge 408B positioned at a first end 410 and a second end 412, respectively, and a post 414 positioned within an interior 416 of the corresponding flux barrier region 404.

[0082] It is noted that for the exemplary laminate 400 shown, the flux barrier region 404 defines a V-shape, has two layers (i.e., two layers at each pole position between the central axis and the periphery along the radial direction R), and is arranged in a quadrupole configuration (i.e., there are four magnetic poles along the circumferential direction C of the laminate 400). However, it should be understood that in other exemplary embodiments, the flux barrier region 404 defined by the body 402 of the laminate 400 can have other suitable shapes and can define any suitable number of layers (see, e.g., Fig. 9 ), and may be arranged in any other suitable pole configuration.

[0083] Still refer to Figure 6 In an exemplary embodiment, as described above, the illustrated laminate 400 may be used to form a portion of an interior permanent magnet motor. Specifically, for the illustrated embodiment, the rotor formed by the illustrated laminate 400 also includes a permanent magnet 418 extending through a flux barrier region 404 defined by the body 402 of the laminate 400. More specifically, for the illustrated embodiment, the permanent magnet 418 is a first permanent magnet 418A, and the rotor also includes a second permanent magnet 418B extending through the flux barrier region 404. One of the plurality of structural elements configured as a column 414 extends through an interior 416 of the flux barrier region 404 at a position between the first permanent magnet 418A and the second permanent magnet 418B.

[0084] In addition, for Figure 6In the embodiment of the present invention, in addition to the pillars 414 and the first and second permanent magnets 418A and 418B, the laminate 400 further includes a flux barrier 420 positioned within the flux barrier region 404. The flux barrier 420 may be a gas, such as air.

[0085] Reference now Figure 7 , a laminate 400 according to another exemplary embodiment of the present disclosure is provided. Figure 7 The exemplary laminate 400 may be similar to the one described above with reference to Figure 6 The exemplary laminate 400 described above is configured in substantially the same manner. Figure 7 In an embodiment of the present invention, the laminate 400 also includes a structural filler 422 that is integrally formed with the body 402 and positioned within the flux barrier region 404 defined by the body 402. The structural filler 422 can be formed of, for example, a non-ferromagnetic material that is different from the second material of one or more structural elements forming the laminate 400. Specifically, for the illustrated embodiment, the laminate 400 includes a plurality of structural elements that are configured as a first bridge 408A located at a first end 410 of the flux barrier region 404, a second bridge 408B located at a second end 412 of the flux barrier region 404, and a column 414 extending through an interior 416 of the flux barrier region 404. The non-ferromagnetic material of the structural filler 422 can define a yield strength that is less than a second yield strength of the second material. In addition, in at least some exemplary embodiments, the yield strength of the structural filler 422 can also be greater than the first yield strength of the first material.

[0086] It is worth noting that for Figure 7 In an embodiment of the present invention, in addition to being integrally formed with the body 402 of the laminate 400, the structural filler 422 is also integrally formed with one of the one or more structural elements.

[0087] In addition, for Figure 7 In an embodiment, structural filler 422 includes multiple portions, including a portion positioned between column 414 and first permanent magnet 418A, a portion positioned between column 414 and second permanent magnet 418B, a portion positioned between first bridge 408A and first permanent magnet 418A, and a portion positioned between second bridge 408B and second permanent magnet 418B.

[0088] In addition, Figure 7 In the embodiment of the present invention, the flux barrier region 404 is a first flux barrier region 404A among the plurality of flux barrier regions 404. Each of the plurality of flux barrier regions 404 includes a structural filler 422 similar to the structural filler 422 described above with reference to the first flux barrier region 404A.

[0089] As described herein, inclusion of structured filler 422 may further provide for higher tip speed capabilities of the resulting electric machine and provide power density limitations for the resulting electric machine.

[0090] Reference now Figure 8 , a laminate 400 according to yet another exemplary embodiment of the present disclosure is provided. Figure 8 The exemplary laminate 400 may be similar to the one described above with reference to Figure 6 The exemplary laminate 400 described above is configured in substantially the same manner. Figure 8 In an embodiment, the laminate 400 also includes an outer ring 424 formed of a third material, which is integrally formed with the body 402 of the laminate 400, one or more structural elements of the laminate 400, or both. The third material is a ferromagnetic material different from the first material forming the body 402 (the first material is also a ferromagnetic material). The third material defines a third yield strength, which is greater than the first yield strength of the first material. For example, the third material can be an iron-containing material, such as iron-cobalt (in this case, the first material can be a silicon-iron composite material, such as Fe-6.5Si). In this way, the outer ring 424 can provide the laminate 400 with the required mechanical strength. In addition, this allows the first material forming the body 402 of the laminate 400 to be, for example, a more economical material. For example, in certain exemplary embodiments, the third material can be an iron-cobalt alloy, while the first material can be a steel with a relatively high silicon content, such as Fe-6.5Si, thereby achieving high rotor efficiency in a more economical manner.

[0091] Reference now Fig. 9 , a laminate 400 according to yet another exemplary embodiment of the present disclosure is provided. Fig. 9 The exemplary laminate 400 may be similar to the one described above with reference to Figure 6 The exemplary laminate 400 described above is configured in substantially the same manner. Fig. 9 In the embodiment shown, the laminate 400 can be used to form a rotor for a synchronous reluctance motor. Thus, for the embodiment shown, the body 402 of the laminate 400 defines a plurality of flux barrier regions 404 in which there are no permanent magnets (see Figures 6 to 8 permanent magnet 418).

[0092] Furthermore, it should be appreciated that for the illustrated embodiment, the flux barrier region 404 defined by the body 402 of the laminate 400 is substantially uniform relative to, for example, Figure 6 The exemplary laminate 400 of is arranged in a unique manner. Specifically, for Fig. 9 In an embodiment, each flux barrier region 404 of the plurality of flux barrier regions 404 defines a U-shape, and the flux barrier regions 404 are arranged in a three-layer configuration at each of the four poles.

[0093] and Figure 6 As in the embodiment of the present invention, the body 402 is formed of a first material, and the laminate 400 includes a structural element formed of a second material integrally with the body 402. Specifically, the structural element is one of a plurality of structural elements, the plurality of structural elements including a first bridge 408A and a second bridge 408B, the first bridge 408A and the second bridge 408B being arranged at a plurality of flux barrier regions 404 and at first ends 410 and second ends 412 of pillars 414, each pillar 414 extending through an interior 416 of a corresponding flux barrier region 404.

[0094] Reference now Fig.10 and 11 , an additional exemplary laminate 400 of the present disclosure is shown. Fig.10 and 11 The exemplary laminate 400 is provided with Fig. 9 The exemplary laminate 400 is configured in a similar manner. However, for Fig.10 In an embodiment, the exemplary laminate 400 further includes a structural filler 422 that is integrally formed with the body 402 and positioned within the flux barrier region 404 defined by the body 402 (similar to, for example, Figure 7 More specifically, for Fig.10 In the embodiment of the present invention, each of the plurality of flux barrier regions 404 includes a structural filler 422 substantially completely positioned therein and integrally formed with the body 402. Specifically, for Fig.10 In an embodiment, the structural filler 422 of each of the plurality of flux barrier regions 404 extends continuously from the column 414 to a first bridge 408A located at the first end 410 of the corresponding flux barrier region 404 , and extends continuously from the column 414 to a second bridge 408B located at the second end 412 of the corresponding flux barrier region 404 .

[0095] It should be understood that in alternative embodiments, laminate 400 may not include posts 414 located within one or more of plurality of flux barrier regions 404, and structural filler 422 may optionally extend continuously from first bridge 408A through respective flux barrier regions 404 to second bridge 408B. Additionally or alternatively, laminate 400 may not include bridge 408, and structural filler 422 may extend continuously from first end 410 through respective flux barrier regions 404 to second end 412 (optionally with posts 414).

[0096] In addition, for Fig.11 In an embodiment, the exemplary laminate 400 further includes an outer ring 424 formed of a third material, the third material being a ferromagnetic material different from the first material and having a yield strength higher than the first yield strength of the first material. Figure 8As with the exemplary embodiment, the exemplary outer ring 424 extends substantially continuously along the perimeter of the laminate 400 (ie, continuously, optionally with the exception of one or more bridges 408).

[0097] Reference now Fig.12 , a laminate 400 according to yet another exemplary embodiment of the present disclosure is provided. Fig.12 The exemplary laminate 400 may be similar to the one described above with reference to Figure 6 The exemplary laminate 400 described above is configured in substantially the same manner. Fig.12 In the embodiment shown, the laminate 400 can be used to form a rotor of a spoke permanent magnet motor. According to the embodiment shown, the body 402 of the laminate 400 defines a plurality of flux barrier regions 404 extending in a radial direction R, each of which is provided with a permanent magnet 418 .

[0098] and Figure 6 The same as the example, Fig.12 The body 402 of the exemplary laminate 400 is formed of a first material, and the laminate 400 also includes a structural element formed of a second material integrally formed with the body 402. The first material is a ferromagnetic material, and the second material is a non-ferromagnetic material having a yield strength higher than a first yield strength of the first material.

[0099] Specifically, for the illustrated embodiment, the structural element is a hub 426 of the laminate 400 , wherein each flux barrier region 404 extends outwardly in a radial direction R from the hub 426 .

[0100] also, Fig.12 The illustrated laminate 400 includes a plurality of additional structural elements configured as bridges 408 , wherein each bridge 408 is positioned along the radial direction R at an outer end 428 of a corresponding flux barrier region 404 .

[0101] Reference now Fig.13 , a laminate 400 according to yet another exemplary embodiment of the present disclosure is provided. Fig.13 The exemplary laminate 400 may be formed with Fig.12 The exemplary laminate 400 is configured in substantially the same manner, however, for Fig.13 In an embodiment of the present invention, the laminate 400 further includes an outer ring 424 formed of a third material. The outer ring 424 is integrally formed with the body 402 of the laminate 400, and the third material is a ferromagnetic material having a yield strength higher than the first yield strength of the first material.

[0102] Reference now Fig.14 , a laminate 400 according to yet another exemplary embodiment of the present disclosure is provided. Fig.14 The exemplary laminate 400 may be similar to the one described above with reference to Figure 6The exemplary laminate 400 is configured in a similar manner as described above. Fig.14 In an embodiment of the present invention, the laminate 400 can be used to form a rotor of a closed rotor slot induction motor. In this manner, the exemplary laminate 400 includes a body 402 that defines a rotor slot 430, and more specifically defines a plurality of rotor slots 430 arranged along the circumference of the body 402. The body 402 is formed of a first material, which is a ferromagnetic material.

[0103] In addition, the laminate 400 includes a structural element integrally formed with the body 402. The structural element is formed of a second material, which is a non-ferromagnetic material having a yield strength higher than a first yield strength of the first material. In the illustrated embodiment, the structural element is configured as a bridge 408, which extends through the opening of a corresponding rotor slot 430 in the plurality of rotor slots 430 at the outer end of the corresponding rotor slot 430 along the radial direction R. More specifically, the laminate 400 includes a plurality of structural elements configured as bridges 408, each of which extends through a corresponding opening of a corresponding rotor slot 430 in the plurality of rotor slots 430.

[0104] The laminate 400 also includes a plurality of rotor bars 432, each rotor bar 432 being positioned in a respective rotor slot 430 of the plurality of rotor slots 430. The rotor bars 432 may be formed of a material different from the first material and different from the second material, such as copper, aluminum, a copper alloy, an aluminum alloy, and the like.

[0105] Reference now Fig.15 , a laminate 400 according to yet another exemplary embodiment of the present disclosure is provided. Fig.15 The exemplary laminate 400 may be similar to the one described above with reference to Fig.14 The exemplary laminate 400 described above is configured in substantially the same manner. Fig.15 In an embodiment of the present invention, the laminate 400 further includes an outer ring 424 formed of a third material (different from the first material) and extending substantially continuously (i.e., continuously, optionally except for one or more bridges 408) along the circumference / periphery of the laminate 400. The third material is a ferromagnetic material having a yield strength higher than the first yield strength of the first material.

[0106] Reference now Fig.16 , showing a method 600 for making a laminate, such as discussed herein and Figure 3-15 . The method 600 begins by producing a body component in step 610. As described herein, the body component can include ferromagnetic material (e.g., part of a body that will subsequently form a laminate) and non-ferromagnetic material (e.g., part of a structural element that will subsequently form a laminate), such as via a multi-material body component. The body component can also include, for example, a near-net-shape rotor or stator of an electric machine.

[0107] Forming the body component in step 610 may include manufacturing the body component by various manufacturing methods. For example, forming the body annular component may include additively manufacturing the body component, such as by LPBF, DED, or via binder jet printing. Even in some embodiments, a portion of the body component may be produced by investment casting of one material, while the remainder of the body component may be constructed by additive manufacturing of another material. For example, forming the component in step 610 may include forming a first portion of a first material, and forming a second portion of a second material on the first portion and integrally formed with the first portion.

[0108] Alternatively, forming the body component in step 610 may simply include providing a previously manufactured body component for use in a subsequent manufacturing step in method 600 .

[0109] Optionally, method 600 may further include heat treating the body component in step 615. The heat treatment in step 615 may include subjecting the body component to one or more elevated temperatures prior to subsequent processing steps to improve mechanical or magnetic properties of the body component. For example, the heat treatment in step 615 may be used to relieve residual stresses in the body component (e.g., from additive manufacturing in step 610), or otherwise change the strength, hardness, or other mechanical or magnetic properties of the body component.

[0110] Continue to refer Fig.16 , method 600 also includes slicing the body component in step 620. The body component can be sliced ​​multiple times in a radial direction (perpendicular to the axial direction) to produce multiple laminates. In some embodiments, the body component can be sliced ​​via electrochemical machining. In some embodiments, the body component can be sliced ​​via electrical discharge machining. The resulting multiple soft magnetic film laminates can then be used in an electric machine, such as a turbine, such as a gas turbine engine.

[0111] Optionally, method 600 may further include surface treating the plurality of laminates in step 630. The surface treatment may include, for example, heat treatment, forming, machining or other surface treatments or a combination thereof. For example, in some embodiments, in step 630, the plurality of laminates may be at least partially coated with an electrical resistant coating.

[0112] The method 600 may also include assembling the laminates to form at least a portion of the motor in step 640. For example, a plurality of soft magnetic thin film laminates may be assembled into a plurality of stacked layers, such as stacked concentrically onto an axis in an axial direction. In some embodiments, each of the plurality of laminates may be separated by a gap. The gap may be electrically insulating, such as by filling with an insulating material to separate each of the plurality of laminates. In some embodiments, the plurality of laminates may be stacked and bonded, such as by chemical bonding via epoxy or other bonding materials. The stacked soft magnetic thin film laminates may be used to form one or more different components of a motor, such as a rotor or a stator.

[0113] Reference now Fig.17 , according to one embodiment of the present disclosure, a perspective view of a rotor 702 is provided. As previously mentioned, the rotor 702 of the electric machine may include two or more rotor laminates. Fig.17 The rotor 702 of FIG. 1 represents one such embodiment of the rotor 106. Fig.17 As shown, the rotor 702 is shown to include 11 rotor laminates 704a to 704k. The rotor laminates 704a to 704k are stacked in a non-tilted configuration in the axial direction A of the motor, as shown in FIG. Fig.17 For example, the rotor laminations 704a to 704k may be stacked in the axial direction A such that the non-ferromagnetic portions (more specifically the non-ferromagnetic bridges 706) of all rotor laminations 704a to 704k are aligned with each other. However, in certain embodiments, according to one embodiment of the present disclosure, the rotor laminations 704a to 704k may be stacked in an inclined configuration along the axial direction A, such as Figures 18A-18C For example, Fig.18A As shown in the rotor configuration of , each rotor laminate is staggered at a fixed angle with adjacent rotor laminates in a single direction (e.g., in a clockwise direction). In some embodiments, the rotor laminates may also be staggered at irregular angles with adjacent rotor laminates. Fig.18B In another example configuration, the rotor laminations are shown tilted in a symmetrical manner relative to the intermediate rotor laminations 704F. Fig.18A and 18B The rotor configuration depicts a stepped tilt of the rotor laminates 704a to 704k. Fig.18A The rotor configuration depicts a stepped tilt of the rotor laminates 704a to 704k. Fig. 18C The rotor configuration of FIG. 7 depicts a sinusoidal tilt of the rotor laminations 704a to 704k. It should be understood that other configurations than Figures 18A-18C Other types of tilting arrangements are shown without limiting the scope of this description.

[0114] The inventors of the present disclosure have discovered that by including a rotor having a laminate of multiple materials as described herein, flux leakage within the rotor can be reduced, thereby allowing for increased torque, but also increased cogging torque or torque ripple. While non-skewed configurations are certainly useful, including such Figures 18A to 18C The tilted configuration shown can reduce torque fluctuations. It is worth noting that tilting can result in a net force in the axial direction (see Fig.18A ). Therefore, by having Fig.18B and 18C The non-linear or mirror-image tilting shown can produce axial forces that cancel each other out.

[0115] Further aspects are provided by the subject matter of the following clauses:

[0116] A rotor of an electric motor, the rotor defining an axial direction and a radial direction, the rotor comprising: a plurality of laminates arranged along the axial direction, the plurality of laminates comprising a first laminate, the first laminate comprising: a body formed of a first material, the first material being a ferromagnetic material; and a structural element integrally formed with the body by a second material, the second material being a non-ferromagnetic material.

[0117] A rotor according to one or more of the preceding clauses, wherein the body defines a flux barrier region, and wherein the structural element is a bridge positioned at an end of the flux barrier region.

[0118] A rotor according to one or more of the preceding clauses, wherein the body defines a flux barrier region, and wherein the structural element is a bridge positioned at an end of the flux barrier region or a column extending through the interior of the flux barrier region, and wherein the rotor further comprises: a permanent magnet extending through the flux barrier region.

[0119] A rotor according to one or more of the preceding clauses, wherein the permanent magnet is a first permanent magnet, wherein the rotor further comprises: a second permanent magnet, the second permanent magnet extending through the flux barrier region, wherein the structural element is the column extending through the interior of the flux barrier region between the first permanent magnet and the second permanent magnet.

[0120] A rotor according to one or more of the preceding clauses, wherein the body defines a flux barrier region, and wherein the structural element is a first structural element, wherein the rotor further comprises: a second structural element, the second structural element being integrally formed with the body from the second material, the first structural element being a first bridge positioned at a first end of the flux barrier region, and the second structural element being a second bridge positioned at a second end of the flux barrier region.

[0121] A rotor according to one or more of the preceding clauses, wherein said structural element is a hub of said first laminate.

[0122] A rotor according to one or more of the preceding clauses, wherein the first material defines a first yield strength, wherein the second material defines a second yield strength, and wherein the second yield strength is greater than the first yield strength.

[0123] A rotor as claimed in one or more of the preceding clauses, wherein the first laminate further comprises: an outer ring formed of a third material, wherein the third material is a ferromagnetic material different from the first material.

[0124] A rotor according to one or more of the preceding clauses, wherein the first material defines a first yield strength, wherein the third material defines a third yield strength, and wherein the third yield strength is greater than the first yield strength.

[0125] A rotor according to one or more of the preceding clauses, wherein the body defines a flux barrier region, and wherein the first laminate further comprises a structural filler formed integrally with the body and positioned in the flux barrier region, wherein the structural filler is formed of a non-ferromagnetic material different from the second material.

[0126] A rotor according to one or more of the preceding clauses, wherein the non-ferromagnetic material of the structural filler defines a yield strength that is less than a second yield strength of the second material.

[0127] A rotor according to one or more of the preceding clauses, wherein the electric machine is a synchronous reluctance machine.

[0128] A rotor according to one or more of the preceding clauses, wherein the electric machine is an interior permanent magnet electric machine.

[0129] A rotor according to one or more of the preceding clauses, wherein said structural element is a hub.

[0130] A rotor according to one or more of the preceding clauses, wherein the electric machine is a spoke permanent magnet electric machine.

[0131] A rotor according to one or more of the preceding clauses, wherein the electric machine is a closed rotor slot induction machine.

[0132] A method for manufacturing a rotor of an electric machine, the rotor defining an axial direction, the method comprising: forming a body component, wherein forming the body component comprises forming a first section from a first material and forming a second section integrally with the first section from a second material, wherein the first material is a ferromagnetic material and the second material is a non-ferromagnetic material; and slicing the body component in a direction perpendicular to the axial direction to produce a plurality of laminates.

[0133] A method according to one or more of the preceding clauses, wherein the slicing is via electrochemical machining.

[0134] The method according to one or more of the preceding clauses, wherein each of the plurality of laminates has a thickness in the axial direction less than or equal to 0.5 mm.

[0135] A method according to one or more of the preceding clauses, wherein forming the main body component includes forming a near-net-shape main body component, the near-net-shape main body component including the first segment and the second segment, the first segment having an annular body surrounding a hollow core extending in the axial direction and defining a flux barrier portion, the second segment being positioned at an end of the flux barrier portion or within the flux barrier portion.

[0136] This written description uses examples to disclose the present disclosure, including the best mode, and also to enable those skilled in the art to practice the present disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the present disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims.

Claims

1. A rotor of an electric motor, the rotor defining an axial direction and a radial direction, characterized in that: The rotor comprises: a plurality of laminated plates, the plurality of laminated plates being arranged along the axial direction, the plurality of laminated plates comprising a first laminated plate, the first laminated plate comprising: a body formed of a first material, the first material being a ferromagnetic material; and A structural element is integrally formed with the body from a second material, the second material being a non-ferromagnetic material.

2. The rotor according to claim 1, characterized in that Wherein the body defines a flux barrier region, and wherein the structural element is a bridge positioned at an end of the flux barrier region.

3. The rotor according to claim 1, characterized in that wherein the body defines a flux barrier region, and wherein the structural element is a bridge positioned at an end of the flux barrier region or a post extending through an interior of the flux barrier region, and wherein the rotor further comprises: A permanent magnet extends through the flux barrier region.

4. The rotor according to claim 3, characterized in that wherein the permanent magnet is a first permanent magnet, wherein the rotor further comprises: A second permanent magnet extends through the flux barrier region, wherein the structural element is the post extending through the interior of the flux barrier region between the first permanent magnet and the second permanent magnet.

5. The rotor according to claim 1, characterized in that wherein the body defines a flux barrier region, and wherein the structural element is a first structural element, wherein the rotor further comprises: A second structural element is formed integrally with the body from the second material, the first structural element being a first bridge positioned at a first end of the flux barrier region, and the second structural element being a second bridge positioned at a second end of the flux barrier region.

6. The rotor according to claim 1, characterized in that Wherein the structural element is a hub of the first laminate.

7. The rotor according to claim 1, characterized in that Wherein the first material defines a first yield strength, wherein the second material defines a second yield strength, and wherein the second yield strength is greater than the first yield strength.

8. The rotor according to claim 1, characterized in that Wherein the first laminate further comprises: An outer ring formed of a third material, wherein the third material is a ferromagnetic material different from the first material.

9. The rotor according to claim 8, characterized in that Wherein the first material defines a first yield strength, wherein the third material defines a third yield strength, and wherein the third yield strength is greater than the first yield strength.

10. The rotor according to claim 1, characterized in that wherein the body defines a flux barrier region, and wherein the first laminate further comprises a structural filler integrally formed with the body and positioned in the flux barrier region, wherein the structural filler is formed of a non-ferromagnetic material different from the second material.

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