Laminated rotor with improved magnet adhesion and method of fabricating

Abstract

In one aspect, a moisture resistant rotor sleeve is provided. The rotor sleeve includes a plurality of stacked laminations forming a sleeve having an outer periphery, an inner periphery, and spaces between adjacent laminations. The rotor sleeve also includes a sealant applied into the spaces between the adjacent laminations, wherein the sealant seals the spaces to prevent air from traveling through the spaces of the sleeve between the inner periphery and the outer periphery.

What is claimed is: 
     
         1 . A moisture resistant rotor sleeve comprising:
 a plurality of stacked laminations forming a sleeve having an outer periphery, an inner periphery, and spaces between adjacent laminations; and   a sealant applied into said spaces between said adjacent laminations, wherein said sealant seals said spaces to prevent air from traveling through said spaces of said sleeve between said inner periphery and said outer periphery.   
     
     
         2 . The rotor sleeve of  claim 1 , wherein said sleeve does not have sealant on at least one of a sleeve inner periphery surface and a sleeve outer periphery surface. 
     
     
         3 . The rotor sleeve of  claim 1 , wherein said sleeve further comprises said sealant on at least one of a sleeve inner periphery surface and a sleeve outer periphery surface. 
     
     
         4 . The rotor sleeve of  claim 1 , wherein said sealant is applied in substantially the entire space between said adjacent laminations from said inner periphery to said outer periphery. 
     
     
         5 . The rotor sleeve of  claim 1 , wherein said sealant is one of a varnish, an anaerobic wicking grade thread locker, a casting porosity sealant, a polyurethane, and an enamel paint. 
     
     
         6 . The rotor sleeve of  claim 1 , further comprising at least one permanent magnet coupled to said sleeve outer periphery, wherein said sealant facilitates preventing moisture from reaching the interface between said outer periphery and said permanent magnet to increase the integrity of the coupling therebetween. 
     
     
         7 . The rotor sleeve of  claim 1 , wherein substantially the entire surface area of said sleeve is coated with said sealant. 
     
     
         8 . A rotor comprising:
 a shaft;   a hub coupled to said shaft;   a plurality of stacked laminations forming a sleeve having an outer periphery, an inner periphery, and spaces between adjacent laminations, said sleeve coupled to said hub;   a sealant applied into said spaces between said adjacent laminations, wherein said sealant seals said spaces to prevent air from traveling through said spaces of said sleeve between said inner periphery and said outer periphery; and   at least one permanent magnet coupled to said sleeve outer periphery, wherein said sealant facilitates preventing moisture from reaching the interface between said outer periphery and said permanent magnet to increase the integrity of the coupling therebetween.   
     
     
         9 . The rotor of  claim 8 , wherein said sleeve does not have sealant on at least one of a sleeve inner periphery surface and a sleeve outer periphery surface. 
     
     
         10 . The rotor of  claim 8 , wherein said sleeve further comprises said sealant on at least one of a sleeve inner periphery surface and a sleeve outer periphery surface. 
     
     
         11 . The rotor of  claim 8 , wherein said sealant is applied in substantially the entire space between said adjacent laminations from said inner periphery to said outer periphery. 
     
     
         12 . The rotor of  claim 8 , wherein said sealant is one of a varnish, an anaerobic wicking grade thread locker, a casting porosity sealant, a polyurethane, and an enamel paint. 
     
     
         13 . The rotor of  claim 8 , wherein substantially the entire surface area of said sleeve is coated with said sealant. 
     
     
         14 . The rotor of  claim 13 , wherein substantially the entire surface area of said at least one permanent magnet is coated with said sealant. 
     
     
         15 . The rotor of  claim 8 , wherein substantially the entire surface area of said rotor is coated with said sealant. 
     
     
         16 . A method of fabricating a moisture resistant rotor sleeve, said method comprising:
 providing a sleeve formed from a plurality of stacked laminations, the sleeve having an outer periphery, an inner periphery, and spaces between adjacent laminations; and   applying a sealant in the spaces between adjacent laminations such that the sealant facilitates sealing the spaces to prevent air from traveling through the spaces of the sleeve between the inner periphery and the outer periphery.   
     
     
         17 . The method of  claim 16 , wherein applying the sealant comprises at least one of spraying the sealant into the spaces, dipping the sleeve in the sealant, brushing the sealant into the spaces, and rolling the sleeve in a shallow bath of the sealant. 
     
     
         18 . The method of  claim 16 , wherein applying the sealant comprises applying a sealant in the spaces between adjacent laminations such that the sealant substantially fills the entire space from the inner periphery to the outer periphery. 
     
     
         19 . The method of  claim 16 , further comprising coupling at least one permanent magnet to the sleeve outer periphery, wherein the sealant facilitates preventing moisture from reaching the interface between the outer periphery and the permanent magnet to increase the integrity of the coupling therebetween. 
     
     
         20 . The method of  claim 19 , wherein at least one of a sleeve outer periphery surface and a sleeve inner periphery surface do not include the sealant.