US 11,870,299 B2
Motor with composite housing
Martin Hosek, Lowell, MA (US); and Christopher Hofmeister, Hampstead, NH (US)
Assigned to Persimmon Technologies, Corp., Wakefield, MA (US)
Filed by Persimmon Technologies, Corp., Wakefield, MA (US)
Filed on Jan. 6, 2016, as Appl. No. 14/988,814.
Claims priority of provisional application 62/100,702, filed on Jan. 7, 2015.
Prior Publication US 2016/0197523 A1, Jul. 7, 2016
Int. Cl. H02K 1/02 (2006.01); H02K 5/02 (2006.01); H02K 15/02 (2006.01)
CPC H02K 1/02 (2013.01) [H02K 5/02 (2013.01); H02K 15/02 (2013.01)] 9 Claims
OG exemplary drawing
 
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.