Manufacturing method and composite powder metal rotor assembly for circumferential type interior permanent magnet machine

摘要

A composite powder metal disk (12) for a rotor assembly (10) in a circumferential type interior permanent magnet machine. The disk (12) includes an inner ring (16) of magnetically conducting powder metal (43) compacted and sintered to a high density. The disk (12) further includes an outer ring (18) of permanent magnets (20) separated by magnetically non-conducting powder metal (47) compacted and sintered to a high density. The permanent magnets (20) additionally are radially embedded by magnetically conducting powder metal (43) compacted and sintered to a high density with optional intermediate non-conducting powder metal bridges (26) extending radially from the permanent magnets (20) to the outer surface (28) of the disk (12). A rotor assembly (10) is also provided having a plurality of the composite powder metal disks (12) mounted axially along a shaft (14) with their magnetic configurations aligned. A method for making the composite powder metal disks (12) is further provided including filling a die (40) with the powder metals (43,47), compacting the powders (43,47), and sintering the compacted powders (43,47).