Magnetic powder metal composite core for electrical machines

Abstract

A compacted magnetic powder metal component assembly for use in an electrical machine is provided. Each component assembly has a top section and a bottom section. Each top section is comprised of a generally cylindrical center portion, a plurality of winding supports extending radially outward from the center portion and a core segment at a radial edge of each winding support. Each bottom section is comprised of a generally cylindrical center portion, a plurality of winding supports extending radially outward from the center portion, and a core segment in a radial edge of each winding segment support. The top section and the bottom section are combined to form the component assembly.

1 . A method of assembling a component for an electrical machine,
 the method comprising providing a top section having a generally cylindrical center portion having a central radial axis,   a plurality of winding supports extending radially outwardly from the center portion,   and a core segment at a radial edge of each winding support,   and having a generally convex outer surface along the radial central axis of the top section,   providing a bottom section having a generally cylindrical center portion, having a central radial axis,   a plurality of winding supports extending radially outward from the center portion,   and a core segment at a radial edge of each winding support,   and having a generally convex outer surface along the radial central axis of the bottom section,   and fitting the top section together such that the top section core segment and the bottom section core segment combine to form a skewed core segment.   
     
     
         2 . The method of  claim 1   wherein each top section core segment comprises a top edge, a bottom edge, and two side edges, with the top edge and the bottom edge being generally parallel, and the two side edges are not parallel.   
     
     
         3 . The method of  claim 1   wherein each top section core segment comprises a top edge, a bottom edge, and two side edges, with the top edge and the bottom edge being generally parallel, and one side edge being perpendicular to the top edge.   
     
     
         4 . The method of  claim 1   wherein each bottom section core segment comprises a top edge, a bottom edge and two side edges, with the top edge and the bottom edge being generally parallel, and the two side edges are not parallel.   
     
     
         5 . The method of  claim 1   wherein each bottom section core segment comprises a top edge, a bottom edge, and two side edges, with the top edge and the bottom edge being generally parallel, and one side edge being perpendicular to the top edge.   
     
     
         6 . The method of  claim 1   wherein each top section core segment has outer edges with a generally trapezoidal configuration.   
     
     
         7 . The method of  claim 1   wherein each bottom section core segment has outer edges with a generally trapezoidal configuration.   
     
     
         8 . The method of  claim 1   wherein the top section core segment and the bottom section core segment when combined form a combined core segment having an outer edge generally forming a parallelogram.   
     
     
         9 . The method of  claim 1   wherein the top section core segment when combined form a combined core segment having a top edge and a bottom edge that are parallel and perpendicular to the central radial axis of the top section of the assembly.   
     
     
         10 . The method of  claim 1   wherein the top section core segment and the bottom section core segment when combined form a combined core segment being a top edge and a bottom edge that are parallel and perpendicular to the central radial axis of the top section of the assembly, and having a first side edge and a second side edge that are generally parallel and are each at an acute angle to the central radial axis of the top section of the assembly.   
     
     
         11 . The method of  claim 1   wherein the top section is comprised of ferrous magnetic metal powder particles.   
     
     
         12 . A method of forming a component for an electrical machine, the method comprising
 providing a die having an inner surface,   providing a first generally cylindrical fill punch which is adjacent the inner surface of the die, and a second generally cylindrical fill punch which includes an inner surface that forms a generally cylindrical opening,   a core rod extending through the generally cylindrical opening in the second fill punch,   filling a cavity formed by the die inner surface, the first fill punch, the second fill punch and the core rod with a ferrous magnetic powder and then compacting the ferrous magnetic powder to form the component for an electrical machine.   
     
     
         13 . The method of  claim 12   wherein the die is generally cylindrical in shape, having a generally cylindrical inner surface,   and wherein the first fill punch is adjacent the inner surface of the die, the first fill punch has a generally cylindrical inner surface,   and the second fill punch is adjacent the inner surface of the first fill punch.   
     
     
         14 . The method of  claim 12   wherein the die is generally cylindrical in shape having a generally cylindrical inner surface,   and further comprising providing an inner die section adjacent the inner surface of the die,   wherein the inner die section forms side edges on the component for an electrical machine.