Rotor structure with non-magnetic filler

Abstract

This disclosure relates to a rotor structure with non-magnetic fillers. A rotor is disclosed that utilizes non-magnetic fillers to reduce magnetic flux leakage and maintain structural integrity. In some embodiments, the rotor includes at least a plurality of rotor laminations, a magnet, and one or more non-magnetic fillers. The plurality of rotor laminations structurally form at least a first cavity and a second cavity; the magnet is disposed in the first cavity; one or more non-magnetic fillers are disposed in the second cavity and engage with the plurality of rotor laminations, and the one or more non-magnetic fillers structurally support the plurality of rotor laminations.

Description

Cross Reference to Related Applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 726,939, filed December 2, 2024, entitled “ROTOR STRUCTURE WITH NON-MAGNETIC FILLER”, the entire technical disclosure of which is incorporated herein by reference. Technical Field

[0002] This invention relates to motor rotors. More specifically, some embodiments of the invention relate to rotor structures utilizing non-magnetic fillers. Background Technology

[0003] Motors used in a variety of applications require robust structural designs to ensure performance and reliability. Internal components must maintain structural integrity under various operating stresses. Current rotor designs typically employ metallic structures (such as steel ribs or steel bridges) to provide structural support for the rotor during operation.

[0004] However, using these metal structures leads to increased magnetic losses. Such losses can adversely affect motor performance, especially under high-speed operating conditions. Therefore, it is necessary to design rotor structures that can reduce magnetic losses and improve motor performance. Summary of the Invention

[0005] In some aspects, the technology described herein relates to a rotor comprising: a plurality of rotor laminations structurally forming at least a first cavity and a second cavity, the plurality of rotor laminations being configured to conduct magnetic flux; a magnet disposed in the first cavity, the magnet being configured to generate magnetic flux; and one or more nonmagnetic fillers disposed in the second cavity and coupled to the plurality of rotor laminations, wherein the one or more nonmagnetic fillers structurally support the plurality of rotor laminations.

[0006] In some respects, the technology described herein relates to a rotor in which one or more nonmagnetic fillers include plastics, epoxy resins, aluminum, fibers, fibrous thermoplastics or thermosetting plastics, composite materials or high-strength composite materials.

[0007] In some respects, the technology described herein relates to a rotor in which a second cavity includes a first finger structure and a second finger structure.

[0008] In some respects, the technology described herein relates to a rotor in which one or more non-magnetic fillers are filled in the gap between a first finger structure and a second finger structure to interlock with a plurality of rotor laminations.

[0009] In some respects, the technology described herein relates to a rotor in which a second cavity at least partially surrounds a plurality of laminations extending from a plurality of rotor laminations into the second cavity.

[0010] In some respects, the technology described herein relates to a rotor in which a plurality of tabs extend from every other rotor lamination into a second cavity.

[0011] In some respects, the technology described herein relates to a rotor in which one or more non-magnetic fillers are filled in the gaps between a plurality of laminations to interlock with a plurality of rotor laminations.

[0012] In some respects, the technology described herein relates to a rotor in which multiple rotor laminations correspond to multiple lamination patterns.

[0013] In some respects, the technology described herein relates to a rotor in which a first rotor lamination of a plurality of rotor laminations includes a first tab of a plurality of tabs, while a second rotor lamination of a plurality of rotor laminations does not include any tab of the plurality of tabs.

[0014] In some respects, the technology described herein relates to a rotor in which multiple rotor laminations correspond to a single lamination pattern.

[0015] In some aspects, the technology described herein relates to a rotor in which a first rotor lamination of a plurality of rotor laminations corresponds to a first orientation during the assembly process, and a second rotor lamination of a plurality of rotor laminations corresponds to a second orientation during the assembly process, and the second orientation is different from the first orientation.

[0016] In some respects, the technology described herein relates to a rotor in which the surfaces of a plurality of convex plates are flat.

[0017] In some respects, the technology described herein relates to a rotor in which the surfaces of a plurality of laminations are formed with wavy or serrated features to increase the contact surface between one or more nonmagnetic fillers and the plurality of rotor laminations.

[0018] In some respects, the technology described herein relates to an electric motor that includes a rotor.

[0019] In some respects, the technology described herein relates to an electric vehicle that includes a rotor.

[0020] In some respects, the technology described herein relates to a rotor comprising: a plurality of rotor laminations structurally forming at least a first cavity and a second cavity; a magnet disposed in the first cavity; and one or more non-magnetic fillers disposed in the second cavity and coupled to the plurality of rotor laminations, wherein the one or more non-magnetic fillers structurally support the plurality of rotor laminations.

[0021] In some respects, the technology described herein relates to a rotor in which one or more nonmagnetic fillers include plastics, epoxy resins, aluminum, fibers, fibrous thermoplastics or thermosetting plastics, composite materials or high-strength composite materials.

[0022] In some respects, the technology described herein relates to a rotor in which a second cavity includes a first finger structure and a second finger structure.

[0023] In some respects, the technology described herein relates to a rotor in which one or more non-magnetic fillers are filled in the gap between a first finger structure and a second finger structure to interlock with a plurality of rotor laminations.

[0024] In some respects, the technology described herein relates to a rotor in which a second cavity at least partially surrounds a plurality of laminations extending from a plurality of rotor laminations into the second cavity.

[0025] In some respects, the technology described herein relates to a rotor in which a plurality of tabs extend from every other rotor lamination into a second cavity.

[0026] In some respects, this paper relates to a rotor in which one or more non-magnetic fillers are filled in the gaps between a plurality of laminations to interlock with a plurality of rotor laminations.

[0027] In some respects, the technology described herein relates to a rotor in which multiple rotor laminations correspond to multiple lamination patterns.

[0028] In some aspects, the technology described herein relates to a rotor in which a first rotor lamination of a plurality of rotor laminations includes a first tab of a plurality of tabs, and in which a second rotor lamination of the plurality of rotor laminations does not include any tab of the plurality of tabs.

[0029] In some respects, the technology described herein relates to a rotor in which multiple rotor laminations correspond to a single lamination pattern.

[0030] In some aspects, the technology described herein relates to a rotor in which a first rotor lamination of a plurality of rotor laminations corresponds to a first orientation during an assembly process, a second rotor lamination of a plurality of rotor laminations corresponds to a second orientation during an assembly process, and wherein the second orientation is different from the first orientation.

[0031] In some respects, the technology described herein relates to a rotor in which the surfaces of a plurality of convex plates are flat.

[0032] In some respects, the technology described herein relates to a rotor in which the surfaces of a plurality of laminations are formed with wavy or serrated features to increase the contact surface between one or more nonmagnetic fillers and the plurality of rotor laminations.

[0033] In some respects, the techniques described herein relate to all embodiments described and discussed above. Attached Figure Description

[0034] Embodiments of this disclosure are described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and in the drawings:

[0035] Figure 1 A top view shows a portion of a rotor that utilizes steel ribs for structural support.

[0036] Figure 2 A top view of a portion of an example rotor according to some embodiments of this disclosure is shown.

[0037] Figure 3A A top view of a portion of an example rotor according to some embodiments of this disclosure is shown.

[0038] Figure 3B Some embodiments according to this disclosure are shown. Figure 3A The example rotor shown is a cross-sectional side view of this part.

[0039] Figure 3C Some embodiments according to this disclosure are shown. Figure 3A The image shows an enlarged view of a portion of the rotor, with some components removed to reveal the rotor's internal structure.

[0040] Figure 4A A cross-sectional side view of a portion of an example rotor according to some embodiments of this disclosure is shown.

[0041] Figure 4B Some embodiments according to this disclosure are shown. Figure 4A The image shows an enlarged view of this part of the example rotor, with some components removed to reveal the rotor's internal structure. Detailed Implementation

[0042] In general, this document discloses rotor structures for motors that enable robust operation in high-speed applications from one or more aspects. More specifically, some embodiments of this disclosure disclose rotor structures that utilize non-magnetic fillers to provide structural support for the rotor and reduce magnetic leakage, thereby improving motor performance. In some embodiments, the non-magnetic fillers (e.g., plastics, epoxy resins, fibers, fibrous thermoplastics or thermosetting plastics, composite materials, high-strength composite materials, etc.) can be formed in various patterns (e.g., finger-like, tabular, sheared, wavy, etc.) in the rotor laminations to mechanically interlock with the rotor laminations, thereby eliminating the need for metal structures such as steel ribs or steel bridges used to ensure the structural integrity of the motor.

[0043] It is worth emphasizing that using non-magnetic fillers, rather than metallic materials or structures, to provide structural support for the rotor can reduce magnetic leakage caused by magnetically conductive metal structures. This, in turn, improves the performance of the rotor and the motor including it, especially in high-speed applications. Additionally, the various patterns formed by the non-magnetic fillers increase the contact surface between the non-magnetic fillers and the rotor laminations, thereby providing a strong mechanical bond between them. These patterns also achieve a strong interlock between the non-magnetic fillers and the rotor laminations, preventing displacement or disengagement of the non-magnetic fillers, rotor laminations, and / or internal rotor magnets during high-speed rotation. Thus, the rotor can withstand operating stresses without compromising its performance and reliability. Furthermore, compared to metallic structures / materials (such as steel ribs), the use of non-magnetic fillers allows for streamlined manufacturing processes, as the non-magnetic fillers can be molded and integrated with the rotor laminations. Replacing steel ribs with non-magnetic fillers also reduces rotor weight, thereby reducing motor inertia and improving dynamic performance.

[0044] Currently, electric motor rotors typically utilize metallic magnetic materials and / or structures to provide structural support for the rotor during operation. For example, steel ribs or bridges are often strategically placed inside the rotor to provide structural support (such as keeping other components within the rotor, such as magnets, in place) and ensure that components associated with the rotor can withstand various operating stresses (such as centrifugal forces during high-speed rotation). While these metallic structures effectively ensure rotor structural integrity, they can introduce magnetic losses. For instance, the magnetic permeability of steel ribs or bridges (such as silicon steel ribs) can cause magnetic flux to short-circuit through the rib or bridge, resulting in a reduction in the magnetic flux participating in energy conversion across the air gap, thereby degrading motor performance.

[0045] To address at least some of the aforementioned problems, some embodiments of this disclosure disclose rotor structures that utilize non-magnetic fillers to provide structural support for the rotor and reduce magnetic losses, rather than using metal structures or materials to provide structural support for the rotor, thereby improving motor performance. In some embodiments, the non-magnetic fillers may be made of plastics, epoxy resins, aluminum, fibers, fibrous thermoplastics or thermosetting plastics, composite materials, and / or high-strength composite materials. (For example, by injecting non-magnetic fillers into cavities formed by the rotor lamination structure), various patterns can be formed in the rotor laminations to mechanically interlock with the rotor laminations, thereby eliminating the need for metal structures such as steel ribs or steel bridges used to ensure the structural integrity of the motor.

[0046] In some embodiments, the nonmagnetic filler or rotor laminations of the rotor may be formed in a finger pattern. For example, the rotor laminations may have multiple finger structures that act as wedges interlocking with the nonmagnetic filler and forming a strong mechanical engagement after the nonmagnetic filler is injected. Specifically, the nonmagnetic filler may fill the space between the finger structures formed by the rotor lamination structure. The interlocking mechanism created by the finger structures between the nonmagnetic filler and the rotor laminations can hold the nonmagnetic filler and rotor laminations together, preventing the nonmagnetic filler from shifting or separating, and / or preventing the various parts of the rotor from loosening or shifting during operation. Advantageously, the structural integrity of the rotor can be maintained.

[0047] In other embodiments, the nonmagnetic filler and / or rotor laminations of the rotor may be formed in any other pattern to ensure interlocking between the nonmagnetic filler and the rotor laminations (e.g., by increasing the contact surface between the nonmagnetic filler and the rotor laminations). For example, in some embodiments, the rotor laminations of the rotor may include one or more tabs extending into a cavity (e.g., a molding cavity) formed by the rotor laminations. The tabs may be rectangular or any other shape and may extend into the cavity in an alternating and / or staggered manner. For example, the rotor laminations of the rotor may include (from top to bottom) a first rotor lamination, a second rotor lamination, a third rotor lamination, a fourth rotor lamination, etc. The first rotor lamination may not include tabs, the second rotor lamination may have a first tab extending into the cavity, the third rotor lamination may not include tabs, and the fourth rotor lamination may have a second tab extending into the cavity.

[0048] In some embodiments, rotor laminations with tabs (e.g., the staggered and / or alternating tabs described above) can be obtained by utilizing different lamination patterns (e.g., using two lamination patterns, wherein the first pattern includes tabs and the second pattern does not). Alternatively or additionally, rotor laminations with tabs can also be obtained by orienting laminations having the same lamination pattern differently (e.g., for a four-pole rotor lamination, the cavities in the first and third poles have tabs, while the cavities in the second and fourth poles do not have tabs, staggered and / or alternating tabs are generated by rotating the first rotor lamination horizontally by 90 degrees and the second rotor lamination by 180 degrees).

[0049] After nonmagnetic filler is injected into the cavity formed by the rotor laminations, the gaps between adjacent laminations can be filled by the nonmagnetic filler. These gaps allow the nonmagnetic filler to flow, fill, and / or engage with the rotor laminations, thereby enhancing the bonding strength between the rotor laminations and the nonmagnetic filler. In some embodiments, the gap length (e.g., the vertical distance of the gap) can be rationally designed to be large enough to reduce magnetic leakage associated with the rotor laminations without excessively increasing the size of the rotor laminations.

[0050] In some embodiments, the surface of the laminations may be flat or planar. In other embodiments, the lamination surface may not be flat but may be characterized by a wavy, serrated, and / or other non-planar structure. For example, the laminations may have a wavy surface or shape. Such wavy surfaces can increase the contact area between the rotor laminations and the non-magnetic filler, thereby enhancing the bonding strength between the rotor laminations and the non-magnetic filler. Advantageously, the rotor formed by the rotor laminations is less likely to fail under operating stresses, such as centrifugal forces subjected to high-speed rotation.

[0051] Although various solutions will be described below in conjunction with illustrative embodiments and combinations of features, those skilled in the art should understand that the examples and combinations of features are merely exemplary in nature and should not be construed as limiting. More specifically, the solutions of this application are applicable to various structural types, motor types, vehicle types, and rotor lamination types in different application scenarios. Furthermore, although specific structures of rotor laminations using non-magnetic fillers to provide structural support and reduce magnetic flux leakage will be described, such exemplary rotor lamination designs or structures should not be construed as limiting. Accordingly, those skilled in the art should understand that the solutions of this application are not necessarily limited to specific types of motors, rotor laminations, rotor assemblies, or exemplary interconnection structures between filler materials and rotor laminations.

[0052] Figure 1 A top view of a portion of a rotor 100, which utilizes steel ribs for structural support, is shown. The rotor 100 includes at least magnets 112, steel bridges(s) 120, steel ribs(s) 104, an air gap 106, and rotor laminations 108. The rotor laminations 108 may comprise thin metal sheets stacked together to form the rotor 100. The rotor laminations 108 may be made of steel and are designed to conduct the magnetic flux generated by the magnets 112 embedded within the rotor 100. It is desirable for the rotor laminations 108 to maintain their structural integrity during high-speed operation.

[0053] Magnet 112 is embedded inside rotor 100 and can generate magnetic flux to drive an electric motor including rotor 100. Magnet 112 may be made of a high-strength magnetic material, such as neodymium or samarium cobalt.

[0054] The air gap 106 can be an intentionally left cavity within the rotor 100. The air gap 106 can be designed to reduce the overall weight of the rotor 100 and / or provide space for the magnet 112 and other components. By reducing the amount of conductive material within the rotor 100, the air gap 106 helps to reduce magnetic leakage.

[0055] Bridge 120 may be a structural component within rotor 100, connecting different portions of rotor lamination 108. Bridge 120 helps maintain magnet 112 and / or rotor lamination 108 in proper position to ensure rotor 100 maintains its shape and structural integrity during operation. Bridge 120 may be made of steel, which may cause magnetic losses due to its conductive properties.

[0056] The steel rib 104 can serve as another structural component within the rotor 100. Similar to the bridge 120, the steel rib 104 provides support for the rotor laminations 108 and securely holds the magnets 112 and / or the rotor laminations 108 in place. The disadvantage of using the steel rib 104 is that it can cause a short circuit in the magnetic flux. Therefore, the steel rib 104 can also lead to magnetic leakage, resulting in a degraded motor performance.

[0057] Figure 2 A top view of a portion of an example rotor 200 according to some embodiments of the present disclosure is shown. The rotor 200 includes at least rotor laminations 208, magnets 112, and non-magnetic fillers 202. Unless otherwise stated, Figure 2 The components can be structurally and functionally related to Figure 1 Components with the same part number are identical or substantially similar. For example, rotor lamination 208 may include stacked metal sheets for conducting magnetic flux generated by magnets 112 embedded within rotor 200. Figure 1 Unlike the implementation method that uses steel ribs 104 to provide structural support for rotor 100, in this embodiment, non-magnetic filler 202 is disposed within rotor 200 (e.g., within rotor laminations 208) to provide structural support and reduce magnetic loss.

[0058] In some embodiments, the nonmagnetic filler 202 may be made of materials such as plastics, epoxy resins, aluminum, fibers, fibrous thermoplastics or thermosetting plastics, composite materials, high-strength composite materials, and combinations thereof. The nonmagnetic filler 202 may fill spaces (e.g., one or more cavities) within the rotor laminations 208 that would otherwise be occupied by a metallic structure (e.g., steel rib 104). As previously described, by replacing the steel rib 104 with the nonmagnetic filler 202, the rotor 200 can achieve structural integrity without the magnetic losses associated with the use of the steel rib 104.

[0059] like Figure 2 As shown, the rotor laminations 208 may be characterized by a plurality of finger structures that act as wedges for interlocking with the nonmagnetic filler 202, thereby creating a strong mechanical engagement after the rotor laminations 208 are injected (e.g., between the rotor laminations 208 and the nonmagnetic filler 202). In some embodiments, each rotor lamination 208 may be characterized by or include the same finger pattern.

[0060] More specifically, the non-magnetic filler 202 can fill the space between the finger-like structures structurally formed by the rotor laminations 208. The interlocking mechanism created by the finger-like structures between the non-magnetic filler 202 and the rotor laminations 208 can hold the non-magnetic filler 202 together with the rotor laminations 208, preventing displacement or detachment of the non-magnetic filler 202, and / or preventing loosening of the components of the rotor 200 during operation. Advantageously, the structural integrity of the rotor 200 can be maintained, especially during high-speed rotation.

[0061] Figure 3A A top view of a portion of an example rotor 300 according to some embodiments of the present disclosure is shown. The rotor 300 includes at least rotor laminations 308, magnets 112, and non-magnetic fillers 302. Unless otherwise stated, Figure 3A The components can be structurally and functionally related to Figure 2 Components with the same number are identical or largely similar. Figure 2 The implementation of the non-magnetic filler 202 forming a finger-like pattern differs from that of the non-magnetic filler 302, which can fill the space (e.g., one or more cavities) within the rotor laminations 308 to form different patterns, which will be referred to Figure 3B and Figure 3C Further explanation. Similar to the non-magnetic filler 202, the non-magnetic filler 302 is disposed within the rotor 300 to provide structural support and reduce magnetic losses associated with the use of the steel rib 104.

[0062] Figure 3B Some embodiments according to this disclosure are shown. Figure 3A A cross-sectional side view of a portion of an example rotor 300. Specifically, Figure 3B The internal structure of a portion of the rotor 300 is shown, including rotor laminations 308, magnets 112, and non-magnetic fillers 302. The rotor laminations 308 are illustrated as stacked together, with the magnets 112 embedded within the rotor 300. The non-magnetic fillers 302 can be injected into the spaces between the rotor laminations 308 (e.g., one or more cavities), thereby creating a robust mechanical engagement that holds the rotor laminations 308 together with the non-magnetic fillers 302. As previously described, this interlocking mechanism advantageously prevents displacement or detachment of the non-magnetic fillers 302 and / or the rotor laminations 308, thus ensuring that the rotor 300 maintains its structural integrity during high-speed rotation.

[0063] like Figure 3BAs shown, the rotor laminations 308 may include different lamination patterns. For example, the first rotor lamination from top to bottom may include a first lamination pattern, the second rotor lamination from top to bottom may include a second lamination pattern, the third rotor lamination from top to bottom may include the first lamination pattern, the fourth rotor lamination from top to bottom may include the second lamination pattern, and so on. The first lamination pattern may provide a larger space for filling the non-magnetic filler 302, while the second lamination pattern may provide a smaller space for filling. In other embodiments, each rotor lamination 308 may have the same lamination pattern, but may be oriented differently (e.g., horizontally rotated) to present different lamination patterns.

[0064] Figure 3C Some embodiments according to this disclosure are shown. Figure 3A An enlarged view of a portion of the example rotor 300, with certain components removed to expose the internal structure of the rotor 300. (See image.) Figure 3C As shown, the rotor 300 includes at least a cavity 320, a lamination 330A, a lamination 330B, and a lamination 330C formed by rotor laminations 308. More specifically, at least some of the non-magnetic fillers 302 are removed from the rotor 300 to expose the cavity 320 formed by the rotor laminations 308.

[0065] like Figure 3C As shown, the rotor laminations 308 include at least tabs 330A, 330B, and 330C extending into the cavity 320 formed by the rotor laminations 308. Tabs 330A, 330B, and 330C may have rectangular or other arbitrary shapes and project into the cavity 320 in an alternating and / or interleaved manner. More specifically, the rotor laminations 308 may include (e.g., from top to bottom): a first rotor lamination, a second rotor lamination, a third rotor lamination, a fourth rotor lamination, etc. The first rotor lamination may not include tabs; the second rotor lamination may include tab 330A projecting into and extending into the cavity 320; the third rotor lamination may not include tabs; the fourth rotor lamination may include tab 330B projecting into and extending into the cavity 320; the fifth rotor lamination may not include tabs; the sixth rotor lamination may include tab 330C projecting into and extending into the cavity 320, and so on.

[0066] As previously described, rotor laminations 308 having tabs 330A, 330B, and 330C can be obtained by utilizing laminations with different lamination patterns (e.g., two lamination patterns: a first lamination pattern including tabs and a second lamination pattern not including tabs). Alternatively and / or additionally, rotor laminations 308 having tabs can also be obtained by orienting laminations having the same lamination pattern differently (e.g., rotating the first rotor lamination horizontally by 90 degrees and the second rotor lamination by 180 degrees).

[0067] In some embodiments, after the nonmagnetic filler 302 is injected into the cavity 320 structurally formed or at least partially surrounded by the rotor laminations 308, the gap between two adjacent tabs (e.g., tabs 330A and 330B) can be filled by the nonmagnetic filler 302. The gap allows the nonmagnetic filler 302 to flow, fill, and / or engage with the rotor laminations 308, thereby enhancing the engagement strength between the rotor laminations 308 and the nonmagnetic filler 302. In some embodiments, the gap length (e.g., the gap distance along the Y direction) can be rationally designed to be sufficiently large without excessively increasing the size of the rotor laminations 308 to reduce magnetic flux leakage associated with the rotor laminations 308.

[0068] Figure 4A A cross-sectional side view of a portion of an example rotor 400 according to some embodiments of the present disclosure is shown. Figure 4A As shown, the rotor 400 includes at least a magnet 112, rotor laminations 408, and non-magnetic filler 402. Unless otherwise stated, Figure 4A The components can be structurally and functionally related to Figure 2 , Figure 3A , Figure 3B and Figure 3C Components with the same number are identical or largely similar. Figure 3B In contrast, the non-magnetic filler 402 forms a wavy feature instead of a flat or planar feature. This wavy feature increases the contact area between the non-magnetic filler 402 and the rotor laminations 408, thereby enhancing the bonding strength between the non-magnetic filler 402 and the rotor laminations 408. This wavy feature will combine... Figure 4B Further explanation.

[0069] Figure 4B Some embodiments according to this disclosure are shown. Figure 4A An enlarged view of a portion of the example rotor 400, with certain components removed to expose the internal structure of the rotor 400. (See image.) Figure 4B As shown, the rotor 400 includes at least a cavity 420, laminations 430A, 430B, and 430C formed by rotor laminations 408. More specifically, at least some non-magnetic fillers 402 are removed from the rotor 400 to expose the cavity 420 formed by the rotor laminations 408. Unless otherwise stated, Figure 4B The components can be structurally and functionally related to Figure 3C Components with the same serial number are identical or largely similar. Figure 3CUnlike the implementation where the tabs 330A, 330B, and 330C are flat, in this embodiment, the tabs 430A, 430B, and / or 430C have a wavy surface or shape. As previously mentioned, the wavy surface of the tabs 430A, 430B, and / or 430C increases the contact surface area between the rotor lamination 408 and the non-magnetic filler 402, thereby enhancing the bonding strength between the rotor lamination 408 and the non-magnetic filler 402. In other embodiments, the surfaces of the tabs 430A, 430B, and / or 430C may exhibit any other non-flat pattern, such as a serrated pattern. Advantageously, the rotor 400 formed by the rotor lamination 408 is less likely to fail under operating stresses, such as centrifugal forces experienced during high-speed rotation.

[0070] The foregoing disclosure is not intended to limit this disclosure to the precise form disclosed or to any particular field of application. Therefore, various alternative embodiments and / or modifications of this disclosure are possible, whether expressly described or implied herein. Since embodiments of this disclosure have been so described, those skilled in the art will recognize that changes in form and detail may be made without departing from the scope of this disclosure. Therefore, this disclosure is defined only by the claims.

[0071] The present disclosure has been described in the foregoing specification with reference to specific embodiments. However, as those skilled in the art will appreciate, the various embodiments disclosed herein can be modified or otherwise implemented in various other ways without departing from the spirit and scope of the invention. Therefore, this specification is intended to be illustrative and to teach those skilled in the art how to make and use various embodiments of the disclosed display components.

[0072] It should be understood that the form of the disclosure shown and described herein should be considered as representative embodiments. Equivalent elements, materials, processes, or steps may be substituted for those representatively shown and described herein. Furthermore, certain features of this disclosure may be utilized independently of the use of other features, all of which will be apparent to those skilled in the art after benefiting from this specification. Expressions such as “comprising,” “including,” “incorporated,” “consisting of,” “having,” and “is” used to describe and claim this disclosure are intended to be interpreted in a non-exclusive manner, allowing for the presence of items, parts, or elements not explicitly described. References to the singular are also interpreted to refer to the plural. Moreover, the various embodiments disclosed herein should be understood in an illustrative and explanatory sense and should in no way be construed as limiting the invention.

[0073] All connecting references (e.g., attachment, affixation, coupling, connection, etc.) are used only to aid the reader in understanding this disclosure and are not intended to impose limitations, particularly regarding the location, orientation, or use of the systems and / or methods disclosed herein. Therefore, connecting references, if any, are to be interpreted broadly. Furthermore, such connecting references do not necessarily imply that two elements are directly connected to each other. Additionally, all numerical terms such as, but not limited to, “first,” “second,” “third,” “primary,” “secondary,” “primary,” or any other common and / or numerical terms should also be considered merely as identifiers to aid the reader in understanding the various elements, embodiments, variations, and / or modifications of this disclosure and are not intended to impose any limitations, particularly regarding the order or preference of any element, embodiment, variation, and / or modification relative to or exceeding another element, embodiment, variation, and / or modification.

[0074] It should also be understood that one or more elements depicted in the accompanying drawings may also be implemented in a more discrete or integrated manner, or even removed or rendered inoperable in some cases, as may be useful for a particular application.

Claims

1. A rotor, comprising: Multiple rotor laminations, structurally forming at least a first cavity and a second cavity, are configured to conduct magnetic flux. A magnet is disposed in the first cavity, the magnet being configured to generate the magnetic flux, and One or more non-magnetic fillers are disposed in the second cavity and are coupled to the plurality of rotor laminations. The one or more non-magnetic fillers therein structurally support the plurality of rotor laminations.

2. The rotor according to claim 1, wherein the one or more non-magnetic fillers comprise plastic, epoxy resin, aluminum, fiber, fibrous thermoplastic or thermosetting plastic, composite material or high-strength composite material.

3. The rotor according to claim 1, wherein the second cavity comprises a first finger structure and a second finger structure.

4. The rotor according to claim 3, wherein the one or more non-magnetic fillers are filled in the gap between the first finger structure and the second finger structure to interlock with the plurality of rotor laminations.

5. The rotor of claim 1, wherein the second cavity at least partially surrounds a plurality of tabs extending from the plurality of rotor laminations into the second cavity.

6. The rotor of claim 5, wherein the plurality of tabs extend from every other rotor lamination of the plurality of rotor laminations into the second cavity.

7. The rotor of claim 6, wherein the one or more non-magnetic fillers fill the gaps between the plurality of laminations to interlock with the plurality of rotor laminations.

8. The rotor according to claim 6, wherein the plurality of rotor laminations correspond to a plurality of lamination patterns.

9. The rotor of claim 8, wherein the first rotor lamination of the plurality of rotor laminations includes a first protrusion of the plurality of protrusions, and wherein the second rotor lamination of the plurality of rotor laminations does not include any of the protrusions of the plurality of protrusions.

10. The rotor of claim 6, wherein the plurality of rotor laminations correspond to a single lamination pattern.

11. The rotor of claim 10, wherein the first rotor lamination of the plurality of rotor laminations corresponds to a first orientation during the assembly process, wherein the second rotor lamination of the plurality of rotor laminations corresponds to a second orientation during the assembly process, and wherein the second orientation is different from the first orientation.

12. The rotor according to claim 5, wherein the surfaces of the plurality of protrusions are flat.

13. The rotor of claim 5, wherein the surfaces of the plurality of laminations are formed with wavy or serrated features to increase the contact surface between the one or more nonmagnetic fillers and the plurality of rotor laminations.

14. An electric motor comprising the rotor according to claim 1.

15. A rotor, comprising: Multiple rotor laminations are stacked to form at least a first cavity and a second cavity in terms of structure; A magnet is disposed in the first cavity; as well as One or more non-magnetic fillers are disposed in the second cavity and joined to the plurality of rotor laminations. The one or more non-magnetic fillers therein structurally support the plurality of rotor laminations.

16. The rotor of claim 15, wherein the second cavity at least partially surrounds a plurality of tabs extending from the plurality of rotor laminations into the second cavity.

17. The rotor of claim 16, wherein the plurality of tabs extend from every other rotor lamination into the second cavity.

18. The rotor of claim 17, wherein the one or more non-magnetic fillers fill the gaps between the plurality of laminations to interlock with the plurality of rotor laminations.

19. The rotor of claim 17, wherein the plurality of rotor laminations correspond to a plurality of lamination patterns.

20. The rotor of claim 19, wherein the first rotor lamination of the plurality of rotor laminations includes a first protrusion of the plurality of protrusions, and wherein the second rotor lamination of the plurality of rotor laminations does not include any of the protrusions of the plurality of protrusions.

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