CPC H02K 1/02 (2013.01) [H02K 5/02 (2013.01); H02K 15/02 (2013.01)] | 9 Claims |
1. An apparatus comprising:
a first member comprising a shell that forms an exterior surface of a housing for a motor assembly;
a drive shaft extending longitudinally through the first member, the drive shaft being rotatable relative to the first member; and
a soft magnetic material formed onto the first member by spray deposition of a magnetic material, the magnetic material being bonded to an inner portion of the shell, the inner portion of the shell comprising a recessed surface defining a cavity, the recessed surface extending continuously around the inner portion of the shell and being equidistant in radial directions from the drive shaft;
wherein the soft magnetic material comprises particles of an iron-containing material built up by a continuous deposition of the particles, each particle having an aluminum oxide coating thereon, a plurality of the particles forming an aggregate of small micro-domains, the micro-domains being separated by oxide insulation boundaries, the soft magnetic material providing a magnetic path that limits losses associated with the formation of eddy currents in the soft magnetic material, and the oxide insulation boundaries limiting electrical conductivity; and
wherein the iron-containing material comprises an iron-aluminum alloy comprising about 89 wt. % iron, about 10 wt. % aluminum, and about 0.25 wt. % carbon; and
wherein the oxide insulation boundaries are aluminum oxide.
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