Permanent-Magnet Rotor Assembly Without Sleeve Energy Loss

The patent removes the metallic sleeve component entirely from the rotor structure. Instead of using a metallic containment system, the invention employs a non-conductive plastic housing with integrated magnet positioning features, thereby eliminating the source of induced currents and energy dissipation while maintaining structural integrity through alternative design means.

The patent substitutes expensive metallic materials with simpler plastic materials that, while having different properties, achieve the containment function without the harmful electromagnetic effects. The plastic housing serves as a disposable or non-renewable structural element that eliminates the need for metallic sleeves.

The patent removes the pre-heating step from the manufacturing process by designing a mold that can directly form the plastic housing around the magnets and core at room temperature or without excessive heating, thereby avoiding thermal discontinuity areas while still achieving corrosion protection through the plastic material itself.

The patent changes the temperature parameter of the molding process to avoid high-temperature pre-heating. By using a modified molding technique that operates at lower temperatures or without pre-heating, the invention prevents thermal discontinuity while maintaining the protective function of the plastic housing.

The patent removes the pre-heating step from the manufacturing process by designing a mold that can directly form the plastic housing around the magnets and core at room temperature or without excessive heating, thereby avoiding thermal discontinuity areas while still achieving corrosion protection through the plastic material itself.

The patent skips the pre-heating step entirely in the molding process. By using a modified molding technique that operates at lower temperatures or without pre-heating, the invention eliminates this time-consuming step while still achieving the desired protective function, thereby reducing overall production time.

The patent applies preliminary action by pre-positioning the magnets in precise locations within the mold cavity before the plastic material is injected. The mold design includes dedicated magnet holders or positioning features that secure the magnets in their final positions before molding begins, preventing any movement during the subsequent plastic material flow and curing process.

The patent introduces an intermediary element in the form of a mold-designed positioning structure or holder that mediates between the magnets and the flowing plastic material. This intermediary structure secures the magnets in place during the molding process, preventing movement while allowing the plastic to flow around them and achieve structural integration.

The patent applies local quality by varying the plastic material thickness in different regions of the rotor housing. Rather than using uniform thickness throughout, the design employs thinner plastic sections where structural resistance is sufficient and thicker sections only where mechanically necessary, thereby minimizing overall rotor volume while maintaining adequate structural strength and maximizing the magnetic gap.

The patent changes the thickness parameter of the plastic material in a non-uniform distribution pattern. By optimizing the thickness parameter locally across different regions of the housing, the invention achieves the minimum necessary structural resistance while minimizing overall volume and maximizing the magnetic gap for improved torque generation.