Granted Patent B2

US 12,374,951 · App. 18/949,800 · Granted Jul 29, 2025

Inventors: Fred Eugene Hunstable (Granbury, TX); Cessar Aguirre (Granbury, TX); Erik Hatch (Frisco, TX)

Assignee: Linear Labs, Inc.

H02K3/50H02K1/278H02K1/30H02K3/04H02K3/28H02K5/225H02K21/14

Abstract

Claims (83)

1. A system comprising:

a segmented stator assembly comprising a set of pole pieces arranged radially about a motor axis:

each pole piece in the set of pole pieces defining:

a rim extending about a periphery of the pole piece;

a recess arranged on a first side of the pole piece; and

a shoulder arranged on a second side, opposite the first side, of the pole piece; and

each pair of adjacent pole pieces, in the segmented stator assembly, defining a pair of linearly-offset and angularly-offset rims that cooperate to define a tapered annular interstice in a radial array of tapered annular interstices;

a set of windings, each winding in the set of windings arranged about a tapered annular interstice in the radial array of tapered annular interstices; and

a rotor:

encompassing the segmented stator assembly; and

comprising a set of magnetic elements configured to magnetically couple to the set of windings to rotate the rotor about the motor axis.

2. The system of claim 1 :

wherein each pair of adjacent pole pieces, in the segmented stator assembly, further defines a shoulder interposed between a pair of linearly-offset and angularly-offset rims that cooperate to define a splayed H-bridge structure in a radial array of splayed H-bridge structures; and

wherein each winding in the set of windings is wound about a shoulder of a splayed H-bridge structure, in the radial array of H-bridge structures, to locate the winding within a tapered annular interstice in the radial array of tapered annular interstices.

3. The system of claim 1 , wherein each pair of adjacent pole pieces, in the segmented stator assembly, comprises:

a first pole piece defining:

a first rim extending about a periphery of the first pole piece; and

a first tapered mating recess arranged on a first side of the first pole piece; and

a second pole piece defining:

a second rim extending about a periphery of the second pole piece; and

a second rectilinear shoulder:

arranged on a second side of the second pole piece, the second side facing the first side of the first pole piece; and

configured to insert within the first tapered mating recess to:

locate the second rim linearly-offset and angularly-offset from the first rim; and

form a tapered annular interstice, in the radial array of tapered annular interstices, between the second rim and the first rim.

4. The system of claim 1 , wherein each pair of adjacent pole pieces, in the segmented stator assembly, comprises:

a first pole piece defining:

a first rim extending about a periphery of the first pole piece; and

a first rectilinear mating recess arranged on a first side of the pole piece; and

a second pole piece defining:

a second rim extending about a periphery of the second pole piece; and

a second tapered shoulder:

arranged on a second side of the second pole piece, the second side facing the first side of the first pole piece; and

configured to insert within the first rectilinear mating recess to:

locate the second rim linearly-offset and angularly-offset from the first rim; and

form a tapered annular interstice, in the radial array of tapered annular interstices, between the second rim and the first rim.

5. The system of claim 1 :

wherein each pole piece in the set of pole pieces further defines a retention feature arranged on the rim extending about the periphery of the pole piece; and

further comprising a retention ring:

arranged coaxial with the motor axis;

nested within an inner radial of the segmented stator assembly; and

defining a set of grooves:

arranged about a periphery of the retention ring; and

configured to mate with retention features of the set of pole pieces to retain the set of pole pieces radially about the motor axis.

6. The system of claim 5 :

wherein the retention ring further defines a bore coaxial with the motor axis; and

further comprising a shaft:

extending through a journal of the retention ring;

coupled to the rotor; and

configured to rotate about the motor axis during magnetic coupling between the set of magnetic elements and the set of windings.

7. The system of claim 1 :

wherein the set of pole pieces define a set of linearly-offset and angularly-offset grooves that cooperate to define a radial channel about an outer radial of the segmented stator assembly; and

further comprising a retention filament:

wound about the radial channel; and

configured to compress the set of pole pieces to maintain the set of pole pieces radially about the motor axis.

8. The system of claim 1 , further comprising a filament:

wound about an outer radial side of the segmented stator assembly to compress the set of pole pieces about the motor axis;

extending across a height of the segmented stator assembly; and

comprising a coating configured to electrically insulate the set of windings from the set of magnetic elements during rotation of the rotor about the segmented stator assembly.

9. The system of claim 1 :

wherein the rotor further comprises:

an inner rotor core:

nested within an inner radial of the segmented stator assembly;

defining a set of inner radial slots arranged about the inner rotor core; and

comprising a subset of inner radial magnetic elements, in the set of magnetic elements, adjacent the set of inner radial slots; and

a first outer plate:

arranged across a first axial side of the segmented stator assembly;

defining a first set of axial slots arranged about the first outer plate; and

comprising a first subset of axial magnetic elements, in the set of magnetic elements, adjacent the first set of axial slots; and

further comprising a shaft:

coupled to the inner rotor core;

coaxial with the motor axis; and

configured to rotate about the motor axis during magnetic coupling between the set of magnetic elements and the set of windings.

10. The system of claim 9 , wherein the rotor further comprises:

an outer rotor wall:

encompassing an outer radial of the segmented stator assembly;

defining a set of outer radial slots arranged about the outer rotor wall; and

comprising a subset of outer radial magnetic elements, in the set of magnetic elements, adjacent the set of outer radial slots; and

a second outer plate:

arranged across a second axial side, opposite the first axial side, of the segmented stator assembly;

defining a second set of axial slots arranged about the second outer plate;

comprising a second subset of axial magnetic elements, in the set of magnetic elements, adjacent the second set of axial slots; and

cooperating with the outer rotor wall, the first outer plate, and the inner rotor core to encompass the set of magnetic elements radially about the segmented stator assembly.

Assignments (1)

Continuity (24)

References Cited (2)

Cited By (1)

US 12,665,452