Rotor structure with non-magnetic filler

Abstract

A rotor is disclosed that utilizes a non-magnetic filler to reduce magnetic flux leakage and maintain structural integrity. [Solution] In some embodiments, the rotor includes at least a plurality of rotor stacks, magnets, and one or more non-magnetic fillers. The plurality of rotor stacks structurally form at least a first cavity and a second cavity. The magnets are placed in the first cavity. One or more non-magnetic fillers are placed in the second cavity and bonded to the plurality of rotor stacks. One or more non-magnetic fillers structurally support the plurality of rotor stacks.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application claims priority to U.S. Provisional Patent Application No. 63 / 726,939, filed on December 2, 2024, with the title "ROTOR STRUCTURE WITH NON - MAGNETIC FILLER", the technical disclosure of which is hereby incorporated by reference in its entirety for all purposes.

[0002] This disclosure relates to the rotor of an electric motor. More particularly, some embodiments of this disclosure relate to rotor structures that utilize non - magnetic fillers.

Background Art

[0003] Electric motors used in various applications require a robust structural design to ensure performance and reliability. Components within an electric motor need to maintain structural integrity under various operating stresses. Current rotor designs often utilize metal structures such as steel ribs or steel bridges to provide structural support to the rotor during operation.

[0004] However, the use of these metal structures can lead to an increase in magnetic losses. These losses can negatively impact motor performance, especially under high - speed operation. Therefore, there may be a desire to design the rotor structure to reduce magnetic losses and improve motor performance.

Summary of the Invention

[0005] In some embodiments, the technology described herein relates to a rotor comprising: a plurality of rotor stacks structurally forming at least a first cavity and a second cavity, wherein the plurality of rotor stacks are configured to conduct magnetic flux; a magnet disposed in the first cavity, wherein the magnet is configured to generate magnetic flux; and one or more non-magnetic fillers disposed in the second cavity and bonded to the plurality of rotor stacks, wherein the one or more non-magnetic fillers structurally support the plurality of rotor stacks.

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

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

[0008] In some embodiments, the technology described herein relates to a rotor in which one or more non-magnetic fillers fill the gaps between a first finger-shaped structure and a second finger-shaped structure in order to engage (interlock) with a plurality of rotor laminates.

[0009] In some embodiments, the technology described herein relates to a rotor in which a second cavity at least partially encloses a plurality of tabs extending into the second cavity from a plurality of rotor stacks.

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

[0011] In some embodiments, the technology described herein relates to a rotor in which one or more nonmagnetic fillers fill the gaps between a plurality of tabs to engage with a plurality of rotor laminates.

[0012] In some embodiments, the technology described herein relates to a rotor in which a plurality of rotor laminates correspond to a plurality of laminate patterns.

[0013] In some embodiments, the technology described herein relates to a rotor in which a first rotor stack of a plurality of rotor stacks includes a first tab of a plurality of tabs, and a second rotor stack of a plurality of rotor stacks does not include any of the tabs of the plurality of tabs.

[0014] In some embodiments, the technology described herein relates to a rotor in which multiple rotor laminates correspond to a single laminate pattern.

[0015] In some embodiments, the technology described herein relates to rotors in which a first rotor stack of a plurality of rotor stacks corresponds to a first orientation (direction) applied during the assembly process, and a second rotor stack of the plurality of rotor stacks corresponds to a second orientation (direction) applied during the assembly process, wherein the second orientation is different from the first orientation.

[0016] In some embodiments, the technology described herein relates to a rotor in which the surfaces of multiple tabs are flat.

[0017] In some embodiments, the technology described herein relates to a rotor in which the surfaces of a plurality of tabs form a wavy or zigzag shape (structure) to increase the contact surface between one or more nonmagnetic fillers and a plurality of rotor laminates.

[0018] In some embodiments, the technology described herein relates to a motor including a rotor.

[0019] In some embodiments, the technology described herein relates to an electric vehicle including a rotor.

[0020] In some embodiments, the technology described herein relates to a rotor comprising a plurality of rotor stacks structurally forming at least a first cavity and a second cavity, magnets disposed within the first cavity, and one or more non-magnetic fillers disposed within the second cavity and bonded to the plurality of rotor stacks, wherein the one or more non-magnetic fillers structurally support the plurality of rotor stacks.

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

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

[0023] In some embodiments, the technology described herein relates to a rotor in which one or more non-magnetic fillers fill the gaps between a first finger-shaped structure and a second finger-shaped structure in order to engage with a plurality of rotor laminates.

[0024] In some embodiments, the technology described herein relates to a rotor in which a second cavity at least partially encloses a plurality of tabs extending into the second cavity from a plurality of rotor stacks.

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

[0026] In some embodiments, the technology described herein relates to a rotor in which one or more nonmagnetic fillers fill the gaps between a plurality of tabs to engage with a plurality of rotor laminates.

[0027] In some embodiments, the techniques described herein relate to a rotor in which a plurality of rotor laminations correspond to a plurality of lamination patterns.

[0028] In some embodiments, the techniques described herein relate 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 a second rotor lamination of the plurality of rotor laminations does not include any of the plurality of tabs.

[0029] In some embodiments, the techniques described herein relate to a rotor in which a plurality of rotor laminations correspond to a single lamination pattern.

[0030] In some embodiments, the techniques described herein relate to a rotor in which a first rotor lamination of a plurality of rotor laminations corresponds to a first orientation applied during an assembly process, and a second rotor lamination of the plurality of rotor laminations corresponds to a second orientation applied during the assembly process, and the second orientation is different from the first orientation.

[0031] In some embodiments, the techniques described herein relate to a rotor in which the surfaces of a plurality of tabs are flat.

[0032] In some embodiments, the techniques described herein relate to a rotor in which the surfaces of a plurality of tabs form a wavy or zigzag shape to increase the contact surface between one or more non-magnetic fillers and a plurality of rotor laminations.

[0033] In some embodiments, the techniques described herein relate to all of the above and foregoing embodiments.

Brief Description of the Drawings

[0034] Embodiments of the present disclosure are described with reference to the accompanying drawings, and like reference numerals refer to like elements.

[0035] [Figure 1] FIG. is a top view of a portion of a rotor that utilizes steel ribs to provide structural support.

[0036] [Figure 2] This is a partial top view of an exemplary rotor according to some embodiments of the present disclosure.

[0037] [Figure 3A] This is a partial top view of an exemplary rotor according to some embodiments of the present disclosure.

[0038] [Figure 3B] This is a cross-sectional side view of an exemplary part of the rotor shown in Figure 3A, according to some embodiments of the present disclosure.

[0039] [Figure 3C] This is an enlarged view of a portion of the exemplary rotor in Figure 3A, with certain parts removed to reveal the internal structure of the exemplary rotor according to some embodiments of the present disclosure.

[0040] [Figure 4A] This is a cross-sectional side view of an exemplary part of a rotor according to some embodiments of the present disclosure.

[0041] [Figure 4B] This is an enlarged view of a portion of the exemplary rotor in Figure 4A, with certain parts removed to reveal the internal structure of the exemplary rotor according to some embodiments of the present disclosure. [Modes for carrying out the invention]

[0042] Generally speaking, one or more aspects of the present disclosure relate to rotor structures for electric motors capable of achieving robust operation under high-speed applications. More specifically, some embodiments of the present disclosure disclose rotor structures that utilize non-magnetic fillers to provide structural support for the rotor, thereby reducing magnetic leakage and thus improving motor performance. In some embodiments, non-magnetic fillers (e.g., plastics, epoxy, fibers, thermoplastic or thermosetting resins with fibers, composite materials, high-strength composite materials, etc.) form various patterns (e.g., fingers, tabs, shears, waves, etc.) on the rotor laminate to mechanically engage (interlock) with the rotor laminate, thereby eliminating the use of metal structures such as steel ribs or steel bridges to ensure the structural integrity of the motor.

[0043] Advantageously, by using non-magnetic fillers instead of metallic materials or structures to provide structural support for the rotor, magnetic leakage caused by metal and magnetic conductive structures can be reduced. This can improve the performance of the rotor and / or the motor including the rotor, especially in high-speed applications. Furthermore, the various patterns formed by the non-magnetic fillers can increase the contact surface between the non-magnetic fillers and the rotor laminate, thereby resulting in a secure mechanical bond between the non-magnetic fillers and the rotor laminate. The various patterns also ensure a secure connection between the non-magnetic fillers and the rotor laminate, preventing the non-magnetic fillers, rotor laminate, and / or magnets within the rotor from shifting or becoming detached under high-speed rotation. Thus, the rotor can withstand operating stresses without compromising its performance or reliability. Moreover, since the non-magnetic fillers can be molded and integrated with the rotor laminate compared to metallic structures / materials (e.g., steel ribs), the use of non-magnetic fillers can streamline the manufacturing process. By using non-magnetic fillers instead of steel ribs, the weight of the rotor can be reduced, which in turn reduces the inertia of the electric motor and improves its dynamic performance.

[0044] Typically, rotors for electric motors utilize metallic and magnetic materials and / or structures to provide structural support for the rotor during operation. For example, steel ribs or steel bridges are usually strategically placed within the rotor to provide structural support (e.g., holding other components such as magnets within the rotor in place) and ensure that components associated with the rotor can withstand various operating stresses (e.g., centrifugal force at high speeds). While these metallic structures can be effective in ensuring the structural integrity of the rotor, they can cause magnetic losses. For example, the magnetic conductivity of steel ribs or steel bridges (e.g., silicon steel ribs) can cause magnetic flux to short-circuit through the steel ribs or steel bridges, resulting in less magnetic flux across the air gap for energy conversion and thus degrading motor performance.

[0045] To address at least some of the above problems, instead of using a metal structure or material to provide structural support for the rotor, some embodiments of the present disclosure disclose a rotor structure that utilizes a non-magnetic filler to provide structural support for the rotor, thereby reducing magnetic loss and improving motor performance. In some embodiments, the non-magnetic filler can be made of plastic, epoxy, aluminum, fiber, thermoplastic or thermosetting resin having fibers, composite materials, and / or high-strength composite materials. The non-magnetic filler can form various patterns on the rotor laminate (for example, by injecting the non-magnetic filler into cavities structurally formed by the rotor laminate) to mechanically connect with the rotor laminate, thereby eliminating the use of metal structures such as steel ribs or steel bridges to ensure the structural integrity of the motor.

[0046] In some embodiments, the non-magnetic filler of the rotor and / or the rotor laminate may form a finger-like pattern. For example, the rotor laminate may feature multiple finger-like structures that act as wedges for connecting with the non-magnetic filler, creating a secure mechanical connection after the non-magnetic filler has been injected. More specifically, the non-magnetic filler may fill the spaces between the finger-like structures structurally formed by the rotor laminate. The connecting mechanism generated by the finger-like structures between the non-magnetic filler and the rotor laminate holds the non-magnetic filler and the rotor laminate together, preventing the non-magnetic filler from shifting or coming loose, and / or preventing various parts of the rotor from being removed or detached during operation. Advantageously, the structural integrity of the rotor can be maintained.

[0047] In other embodiments, the nonmagnetic fillers and / or rotor laminates of the rotor may form any other patterns to ensure connectivity between the nonmagnetic fillers and / or between the rotor laminates (for example, by increasing the contact surface between the nonmagnetic fillers and the rotor laminates). For example, in some embodiments, the rotor laminates of the rotor may include one or more tabs extending into the cavity formed by the rotor laminates (e.g., a molded cavity). The tabs may be rectangular or any other shape and may protrude into the cavity in a staggered and / or alternating manner. For example, the rotor laminates of the rotor may include (e.g., from top to bottom) a first rotor laminate, a second rotor laminate, a third rotor laminate, a fourth rotor laminate, and so on. The first rotor laminate may not include tabs, the second rotor laminate may have a first tab extending into the cavity, the third rotor laminate may not include tabs, and the fourth rotor laminate may have a second tab extending into the cavity.

[0048] In some embodiments, rotor laminates having tabs (e.g., staggered tabs and / or alternating tabs as described above) can be obtained by utilizing laminates having various laminate patterns (e.g., two laminate patterns, one in which a first laminate pattern includes tabs and the other in which a second laminate pattern does not). Alternatively and / or additionally, rotor laminates having tabs can be obtained by orienting laminates having the same laminate pattern in different ways (for example, in the case of a quadrupole rotor laminate, the cavities of the first and third poles have tabs, while the cavities of the second and fourth poles do not, and staggered tabs and / or alternating tabs are generated by rotating the first rotor laminate 90 degrees horizontally and the second rotor laminate 180 degrees).

[0049] After the non-magnetic filler is injected into the cavity structurally formed by the rotor laminate, the gap between two adjacent tabs can be filled with the non-magnetic filler. The gap allows the non-magnetic filler to flow into, fill, and / or bond with the rotor laminate to increase the bonding strength between the rotor laminate and the non-magnetic filler. In some embodiments, the length of the gap (e.g., the vertical distance of the gap) can be appropriately designed to be large enough to reduce the leakage flux associated with the rotor laminate without excessively increasing the size of the rotor laminate.

[0050] In some embodiments, the surface of the tab may be flat or planar. In other embodiments, the surface of the tab may not be flat and may feature a corrugated, zigzag, and / or other non-planar structure. For example, the tab may have a corrugated surface or shape. A corrugated surface of the tab can increase the size of the contact surface between the rotor laminate and the non-magnetic filler, thereby increasing the bonding strength between the rotor laminate and the non-magnetic filler. Advantageously, the rotor formed by the rotor laminate may be less likely to fail under operating stresses such as centrifugal force that can withstand high-speed rotation.

[0051] Various embodiments will be described according to exemplary combinations of embodiments and features, but those skilled in the art will understand that the examples and combinations of features are illustrative in nature and should not be construed as limiting. More specifically, embodiments of this application are applicable to various types of structures, electric motors, vehicles, and rotor stacks under various circumstances. Furthermore, specific structures of rotor stacks that utilize non-magnetic fillers to provide structural support and reduce leakage flux will be described, but such exemplary rotor stack designs or structures should not be construed as limiting. Accordingly, those skilled in the art will understand that embodiments of this application are not necessarily limited to any particular type of electric motor, rotor stack, rotor assembly, or exemplary interconnections between fillers and rotor stacks.

[0052] Figure 1 shows a partial top view of a rotor 100 that utilizes steel ribs to provide structural support. The rotor 100 includes at least magnets 112, a steel bridge 120, steel ribs 104, air pockets 106, and a rotor stack 108. The rotor stack 108 may include thin sheets of metal stacked together to form the rotor 100. The rotor stack 108 may be made of steel and is designed to conduct the magnetic flux generated by the magnets 112 embedded in the rotor 100. It is desirable that the rotor stack 108 maintain their structural integrity during high-speed operation.

[0053] The magnet 112 is embedded within the rotor 100 and can generate a magnetic flux to drive the motor, including the rotor 100. The magnet 112 can be made of a high-strength magnetic material such as neodymium or samarium-cobalt.

[0054] The air pocket 106 can be an intentional gap within the rotor 100. The air pocket 106 can be designed to reduce the overall weight of the rotor 100 and / or to provide space for the magnet 112 and other components. The air pocket 106 can help reduce magnetic leakage by reducing the amount of conductive material within the rotor 100.

[0055] The bridge 120 can be a structural component within the rotor 100 and can connect various parts of the rotor stack 108. The bridge 120 can help hold the magnets 112 and / or the rotor stack 108 in place to ensure that the rotor 100 maintains its shape and structural integrity during operation. The bridge 120 can be made of steel, which may result in magnetic losses due to its conductivity.

[0056] The steel rib 104 can function as another structural component within the rotor 100. Similar to the bridge 120, the steel rib 104 provides support to the rotor stack 108, allowing the magnets 112 and / or the rotor stack 108 to be held firmly in place. A disadvantage of utilizing the steel rib 104 is that it can short-circuit the magnetic flux through it. Thus, the steel rib 104 can also cause magnetic leakage, resulting in reduced motor performance.

[0057] Figure 2 shows a partial top view of an exemplary rotor 200 according to several embodiments of the present disclosure. The rotor 200 includes at least a rotor laminate 208, magnets 112, and a non-magnetic filler 202. Unless otherwise noted, the components of Figure 2 may be structurally and functionally the same or substantially the same as the components of similar number in Figure 1. For example, the rotor laminate 208 may include thin sheets of metal stacked on top of each other to conduct the magnetic flux generated by the magnets 112 embedded in the rotor 200. In contrast to the implementation in Figure 1 in which steel ribs 104 are used to provide structural support for the rotor 100, the non-magnetic filler 202 is arranged within the rotor 200 (e.g., within the rotor laminate 208) to provide structural support and reduce magnetic loss.

[0058] In some embodiments, the non-magnetic filler 202 can be made of materials such as plastics, epoxy, aluminum, fibers, fibrous thermoplastic or thermosetting resins, composite materials, high-strength composite materials, and / or combinations thereof. The non-magnetic filler 202 can fill spaces (e.g., one or more cavities) within the rotor laminate 208 that are normally occupied by metal structures (e.g., steel ribs 104). As described above, by replacing the steel ribs 104 with the non-magnetic filler 202, the rotor 200 can achieve structural integrity without the magnetic losses associated with the use of steel ribs 104.

[0059] As shown in Figure 2, the rotor laminate 208 may feature a plurality of finger-like structures that act as wedges to connect with the non-magnetic filler 202 in order to form a secure mechanical bond (e.g., between the rotor laminate 208 and the non-magnetic filler 202) after the non-magnetic filler 202 has been injected. In some embodiments, each of the rotor laminate 208 may feature or include the same finger-like pattern.

[0060] More specifically, the non-magnetic filler 202 may fill the spaces between the finger-like structures structurally formed by the rotor laminate 208. The connecting mechanism generated by the finger-like structures between the non-magnetic filler 202 and the rotor laminate 208 holds the non-magnetic filler 202 and the rotor laminate 208 together, preventing the non-magnetic filler 202 from shifting or coming loose, and / or preventing various parts of the rotor 200 from being removed during operation. Advantageously, the structural integrity of the rotor 200 can be maintained, particularly during high-speed rotation.

[0061] Figure 3A shows a partial top view of an exemplary rotor 300 according to several embodiments of the present disclosure. The rotor 300 includes at least a rotor laminate 308, magnets 112, and a non-magnetic filler 302. Unless otherwise noted, the components of Figure 3A may be structurally and functionally the same or substantially the same as the components of similar number in Figure 2. In contrast to the implementation in Figure 2 in which the non-magnetic filler 202 forms a finger-like pattern, the non-magnetic filler 302 may fill spaces (e.g., one or more cavities) within the rotor laminate 308 to form distinct patterns, as further shown with reference to Figures 3B and 3C. Similar to the non-magnetic filler 202, the non-magnetic filler 302 is positioned within the rotor 300 to provide structural support and reduce magnetic losses associated with the use of steel ribs 104.

[0062] Figure 3B shows a partial cross-sectional side view of an exemplary rotor 300 of Figure 3A according to several embodiments of the present disclosure. More specifically, Figure 3B shows a partial internal structure of the rotor 300, including a rotor stack 308, magnets 112, and a non-magnetic filler 302. The rotor stack 308 is shown stacked together with the magnets 112 embedded within the rotor 300. The non-magnetic filler 302 can be injected into the spaces between the rotor stack 308 (e.g., one or more cavities) to create a secure mechanical bond that holds the rotor stack 308 and the non-magnetic filler 302 together. As described above, this coupling mechanism can advantageously prevent the non-magnetic filler 302 and / or the rotor stack 308 from shifting or coming loose, in order to ensure the maintenance of structural integrity during high-speed rotation of the rotor 300.

[0063] As shown in Figure 3B, the rotor stack 308 can include various stack patterns. For example, the first rotor stack from the top may include a first stack pattern, the second rotor stack from the top may include a second stack pattern, the third rotor stack from the top may include a first stack pattern, the fourth rotor stack from the top may include a second stack pattern, and so on. The first stack pattern can provide ample space for filling with the non-magnetic filler 302, while the second stack pattern can provide less space for filling with the non-magnetic filler 302. In other embodiments, each of the rotor stacks 308 may have the same stack pattern but can be oriented in various ways (e.g., rotated horizontally) to feature various stack patterns.

[0064] Figure 3C shows a magnified view of a portion of the exemplary rotor 300 from Figure 3A, with certain parts removed to reveal the internal structure of the exemplary rotor 300 according to some embodiments of the present disclosure. As shown in Figure 3C, the rotor 300 includes a rotor laminate 308, tabs 330A, 330B, and 330C, and at least a cavity 320 formed by these tabs. More specifically, at least some non-magnetic filler 302 is removed from the rotor 300 to reveal the cavity 320 formed by the rotor laminate 308.

[0065] As shown in Figure 3C, the rotor stack 308 includes at least tabs 330A, 330B, and 330C extending into the cavity 320 formed by the rotor stack 308. The tabs 330A, 330B, and 330C may be rectangular or any other shape and may protrude in a staggered pattern and / or alternately into the cavity 320. More specifically, the rotor stack 308 may include (e.g., from top to bottom) a first rotor stack, a second rotor stack, a third rotor stack, a fourth rotor stack, and so on. The first rotor stack may not include tabs, the second rotor stack may include tabs 330A protruding and extending into the cavity 320, the third rotor stack may not include tabs, the fourth rotor stack may include tabs 330B protruding and extending into the cavity 320, the fifth rotor stack may not include tabs, the sixth rotor stack may include tabs 330C protruding and extending into the cavity 320, and so on.

[0066] As described above, a rotor laminate 308 having tabs 330A, 330B, and 330C can be obtained by utilizing laminates having various laminate patterns (for example, two laminate patterns in which a first laminate pattern includes tabs and a second laminate pattern does not). Alternatively and / or additionally, a rotor laminate 308 having tabs 330A, 330B, and 330C can be obtained by orienting laminates having the same laminate pattern in different ways (for example, rotating the first rotor laminate horizontally by 90 degrees and rotating the second rotor laminate by 180 degrees).

[0067] In some embodiments, after the non-magnetic filler 302 is injected into a cavity 320 structurally formed by the rotor laminate 308, or at least partially enclosed, the gap between two adjacent tabs (e.g., tabs 330A and 330B) can be filled with the non-magnetic filler 302. The gap allows the non-magnetic filler 302 to flow into, fill, and / or bond with the rotor laminate 308 in order to increase the bonding strength between the rotor laminate 308 and the non-magnetic filler 302. In some embodiments, the length of the gap (e.g., the distance of the gap along the "Y" direction) can be appropriately designed to be sufficiently large to reduce the leakage flux associated with the rotor laminate 308 without excessively increasing the size of the rotor laminate 308.

[0068] Figure 4A shows a partial cross-sectional side view of an exemplary rotor 400 according to several embodiments of the present disclosure. As shown in Figure 4A, the rotor 400 includes at least a magnet 112, a rotor laminate 408, and a non-magnetic filler 402. Unless otherwise noted, the components of Figure 4A may be structurally and functionally the same or substantially the same as the components of similar numbers in Figures 2, 3A, 3B, and 3C. In contrast to the mounting configuration of Figure 3B, the non-magnetic filler 402 forms a corrugated feature rather than a flat or planar feature. The corrugated feature can increase the size of the contact surface between the non-magnetic filler 402 and the rotor laminate 408, thereby increasing the bonding strength between the non-magnetic filler 402 and the rotor laminate 408. The corrugated feature is further illustrated below with reference to Figure 4B.

[0069] Figure 4B shows a magnified view of a portion of the exemplary rotor 400 of Figure 4A, with certain parts removed to reveal the internal structure of the exemplary rotor 400 according to several embodiments of the present disclosure. As shown in Figure 4B, the rotor 400 includes a rotor laminate 408, tabs 430A, 430B, and 430C, and at least a cavity 420 formed by these tabs. More specifically, at least some non-magnetic filler 402 is removed from the rotor 400 to reveal the cavity 420 formed by the rotor laminate 408. Unless otherwise noted, the components of Figure 4B may be structurally and functionally the same or substantially the same as the components of similar number in Figure 3C. In contrast to the mounting configuration of Figure 3C, where tabs 330A, 330B, and 330C are flat, tabs 430A, 430B, and / or 430C have a corrugated surface or shape. As described above, the corrugated surfaces of tabs 430A, 430B, and / or 430C can increase the contact surface area between the rotor laminate 408 and the non-magnetic filler 402, thereby increasing the bonding strength between the rotor laminate 408 and the non-magnetic filler 402. In other embodiments, the surfaces of tabs 430A, 430B, and / or 430C may exhibit any other non-flat patterns, such as a zigzag pattern. Advantageously, the rotor 400 formed by the rotor laminate 408 may be less likely to fail under operating stresses such as centrifugal force during high-speed rotation.

[0070] The foregoing disclosure is not intended to limit the disclosure to the exact form or specific field of use disclosed. Therefore, various alternative embodiments and / or modifications to the disclosure, whether expressly described or implied herein, are possible in light of the disclosure. While embodiments of the disclosure have been described in this manner, those skilled in the art will recognize that modifications in form and detail are possible without departing from the scope of the disclosure. Therefore, the disclosure is limited solely by the claims.

[0071] The above specification has described the present disclosure with reference to specific embodiments. However, as those skilled in the art will understand, the various embodiments disclosed herein can be modified or implemented in various other ways without departing from the spirit and scope of the disclosure. Therefore, this description should be considered illustrative and is intended to teach those skilled in the art how to create and use various embodiments of the disclosed display assemblies.

[0072] It should be understood that the forms of disclosure shown and described herein should be interpreted 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 used independently of the use of other features, as will become apparent to those skilled in the art after benefiting from this description of the disclosure. Expressions such as “includes,” “equipment,” “contains,” “consistes of,” “has,” and “is” used to describe and claim this disclosure are intended to be interpreted in a non-exclusive manner, that is, to allow for the existence of items, components, or elements not expressly described herein. Singular references should also be interpreted in relation to plurals. Furthermore, the various embodiments disclosed herein should be interpreted in an illustrative and descriptive sense and should not be interpreted in any way as limiting this disclosure.

[0073] All references to joinings (e.g., attachment, fastening, joining, connection, etc.) are used solely to aid the reader's understanding of this disclosure and do not imply any limitation with respect to the location, orientation, or use of the systems and / or methods disclosed herein. Therefore, where there is a reference to joining, it should be interpreted broadly. Furthermore, such reference to joining does not necessarily imply that the two elements are directly connected to each other. Additionally, but not limited to, all numerical terms such as “first,” “second,” “third,” “primary,” “secondary,” “main,” or any other common and / or numerical terms should also be interpreted solely as identifiers to aid the reader's understanding of the various elements, embodiments, variations, and / or modifications of this disclosure and do not imply any limitation with respect to the order or priority of any element, embodiment, variation, and / or modification, or to the order or priority of another element, embodiment, variation, and / or modification.

[0074] It will also be understood that, depending on the specific application, one or more of the elements shown in the drawings / figures may be implemented in a separate or integrated manner, or in certain cases may be removed or abandoned as non-functional.

Claims

1. It is a rotor, A plurality of rotor stacks structurally forming at least a first cavity and a second cavity, wherein the plurality of rotor stacks are configured to conduct magnetic flux, A magnet disposed within the first cavity, wherein the magnet is configured to generate the magnetic flux, One or more non-magnetic fillers are disposed within the second cavity and bonded to the plurality of rotor laminates, Equipped with, A rotor in which one or more nonmagnetic fillers structurally support the plurality of rotor laminates.

2. The rotor according to claim 1, wherein the one or more nonmagnetic fillers include plastic, epoxy, aluminum, fiber, a thermoplastic or thermosetting resin having fibers, a composite material, or a high-strength composite material.

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

4. The rotor according to claim 3, wherein one or more nonmagnetic fillers fill the gap between the first finger-shaped structure and the second finger-shaped structure in order to engage with the plurality of rotor laminates.

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

6. The rotor according to claim 5, wherein the plurality of tabs extend into the second cavity from every other rotor stack among the plurality of rotor stacks.

7. The rotor according to claim 6, wherein one or more nonmagnetic fillers fill the gaps between the multiple tabs in order to engage with the multiple rotor laminates.

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

9. The rotor according to claim 8, wherein the first rotor stack of the plurality of rotor stacks comprises the first tab of the plurality of tabs, and the second rotor stack of the plurality of rotor stacks does not comprise any of the tabs of the plurality of tabs.

10. The rotor according to claim 6, wherein the plurality of rotor laminates correspond to a single laminate pattern.

11. The rotor according to claim 10, wherein the first rotor stack of the plurality of rotor stacks corresponds to a first orientation applied during the assembly process, and the second rotor stack of the plurality of rotor stacks corresponds to a second orientation applied during the assembly process, the second orientation being different from the first orientation.

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

13. The rotor according to claim 5, wherein the surfaces of the plurality of tabs form a wavy or zigzag shape to increase the contact surface between the one or more nonmagnetic fillers and the plurality of rotor laminates.

14. A motor comprising the rotor described in claim 1.

15. It is a rotor, A plurality of rotor laminates structurally forming at least a first cavity and a second cavity, A magnet placed in the first cavity, One or more non-magnetic fillers are disposed within the second cavity and bonded to the plurality of rotor laminates, Equipped with, A rotor in which one or more nonmagnetic fillers structurally support the plurality of rotor laminates.

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

17. The rotor according to claim 16, wherein the plurality of tabs extend into the second cavity from every other rotor stack among the plurality of rotor stacks.

18. The rotor according to claim 17, wherein one or more nonmagnetic fillers fill the gaps between the multiple tabs in order to engage with the multiple rotor laminates.

19. The rotor according to claim 17, wherein the plurality of rotor laminates correspond to a plurality of laminate patterns.

20. The rotor according to claim 19, wherein the first rotor stack of the plurality of rotor stacks comprises the first tab of the plurality of tabs, and the second rotor stack of the plurality of rotor stacks does not comprise any of the tabs of the plurality of tabs.

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