Einzeltreffer — DigiBib

A Magnetic Gear Modulator (MGM) of a Concentric Magnetic Gear (CMG) is manufactured by injection molding a modulator cage over angularly spaced apart MGM pole pieces made of a magnetically conducting material. The pole pieces are initially connected by a support ring, or held by a fixture. The modulator cage is preferably a thermally conductive strengthening fiber filled plastic, a carbon fiber plastic, a carbon fiber filled plastic material, a glass material, or a high performance composite plastic molding material. After molding, the outer and/or inner portions of the molding material, and support ring if present, are machined away preferably exposing both inner and outer faces of the pole pieces embedded in the modulator cage. An MGM made using injection molding over a connected support ring and pole pieces reduces cost, and a carbon fiber plastic modulator cage increases strength.

Titel:	Injection Molding a Modulator Support Cage
Link:	View record in USPTO Patent Applications (Volltext)
Veröffentlichung:	2022
Medientyp:	Patent
Sonstiges:	Nachgewiesen in: USPTO Patent Applications Sprachen: English Document Number: 20220278601 Publication Date: September 1, 2022 Appl. No: 17/665342 Application Filed: February 04, 2022 Claim: 1. A method for manufacturing a Magnetic Gear Modulator (MGM) of a Concentric Magnetic Gear (CMG), the method comprising: forming a support ring connected to pole pieces of the MGM, of a magnetically conducting material; molding a molding material between pole pieces; and machining off the support ring leaving angularly spaced apart pole pieces connected by the molding material. Claim: 2. The method of claim 1, wherein: the support ring is an outer support ring residing outside the pole pieces; and the machining off the support ring includes exposing an outer face of the pole pieces. Claim: 3. The method of claim 1, wherein: the support ring is an inner support ring residing inside the pole pieces; and the machining off the support ring includes exposing an inner face of the pole pieces. Claim: 4. The method of claim 1, wherein: the support ring is at least one end ring; and including machining off the at least one end ring. Claim: 5. The method of claim 1, wherein the molding material is injection molding material. Claim: 6. The method of claim 5, wherein the injection molding material is a thermally conductive strengthening fiber filled plastic. Claim: 7. The method of claim 6, wherein the thermally conductive strengthening fiber filled plastic is selected from the group consisting of thermally conductive strengthening fiber filled plastic, a carbon fiber plastic, a carbon fiber filled plastic material, a glass material, and a high performance composite plastic. Claim: 8. The method of claim 1, wherein the magnetic material is a ferromagnetic material. Claim: 10. The method of claim 9, wherein the ferromagnetic material is selected from the group consisting of a bulk magnetic or metallic glass, a laminated bulk magnetic glass, or Soft Magnetic Composites (SMC). Claim: 11. The method of claim 1, wherein forming pole pieces comprises forming non-round cross-section pole pieces. Claim: 12. The method of claim 11, wherein the forming non-round cross-section pole pieces comprises forming pole pieces having an hour glass shaped cross-section. Claim: 13. The method of claim 1, wherein forming pole pieces comprises forming pole pieces including forming pole pieces having features resisting rotating in the MGM. Claim: 14. The method of claim 1, wherein forming the forming a support ring and pole pieces comprises forming a single piece casting. Claim: 15. A Magnetic Gear Modulator (MGM) of a Concentric Magnetic Gear (CMG), comprising: a raw MGM comprising: a cast single piece support ring and angularly spaced apart pole pieces reaching in or out from the support ring, the casting made of magnetically conductive material; and a high performance composite plastic, thermally conductive molding material molded between the pole pieces; a machined MGM comprising a machined outer or inner face of the raw MGM and exposed inner and outer faces of the pole pieces. Claim: 16. A method for manufacturing a Magnetic Gear Modulator (MGM) of a Concentric Magnetic Gear (CMG), the method comprising: casting a single piece support ring and pole pieces of the MGM, of a magnetically conducting material wherein: the support ring resides outside the pole pieces, or inside the pole pieces, or at an end of the pole pieces; and the pole pieces has a non-round cross-section to resist rotating in the MGM; injection molding a high performance composite plastic, thermally conductive injection molding material between the pole pieces; machining off the support rings leaving exposed inner or outer faces of the pole pieces; leaving the pole pieces connected by the injection molded material; and assembling the CMG including the MGM between inner and outer rotors. Current International Class: 02; 29; 29; 02

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Injection Molding a Modulator Support Cage