US3858308A — Process for making a rotor assembly

Claim 1

Independent Claim 168 words

A PROCESS FOR MAKING AN INTEGRAL ROTOR ASSEMBLY COMPRISED OF A FERROMAGNETIC HUB AND A RING-SHAPED COBALT ALLOY MAGNET, SAID PROCESS COMPRISING: APPLYING A COATING OF INERT MATERIAL HAVING A MELTING POINT ABOVE THE SINTERING TEMPERATURE OF SAID COBALT ALLOY TO THE SURFACE OF SAID FERROMAGNETIC HUB; PLACING SAID HUB IN AN ANNULAR DIE CAVITY HAVING A CENTRAL AXIS SO THAT THE CENTRAL AXIS OF SAID HUB IS COAXIAL WITH SAID CENTRAL AXIS OF SAID DIE CAVITY; SURROUNDING THE OUTSIDE HUB WITH METAL PARTICLES BY FILLING SAID DIE CAVITY WITH METAL PARTICLES CONSISTING ESSENTIALLY OF COBALT AND AT LEAST ONE RARE EARTH METAL; ESTABLISHING A MAGNETIC FIELD THROUGH THE CONTENTS OF SAID DIE CAVITY, SAID MAGNETIC FIELD RADIALLY ORIENTED WITH RESPECT TO THE CENTRAL AXIS OF SAID DIE CAVITY; APPLYING PRESSURE TO THE CONTENTS OF SAID DIE CAVITY TO COMPACT SAID METAL PARTICLES INTO A SOLID ONE-PIECE ANNULAR MEMBER; AND APPLYING SUFFICIENT HEAT TO SINTER SAID METAL PARTICLES TO THE COATED HUB, THEREBY FORMING AN INTEGRAL ROTOR ASSEMBLY.

Claim 2

Dependent Claim 168 words

A PROCESS FOR MAKING AN INTEGRAL ROTOR ASSEMBLY COMPRISED OF A FERROMAGNETIC HUB AND A RING-SHAPED COBALT ALLOY MAGNET, SAID PROCESS COMPRISING: APPLYING A COATING OF INERT MATERIAL HAVING A MELTING POINT ABOVE THE SINTERING TEMPERATURE OF SAID COBALT ALLOY TO THE SURFACE OF SAID FERROMAGNETIC HUB; PLACING SAID HUB IN AN ANNULAR DIE CAVITY HAVING A CENTRAL AXIS SO THAT THE CENTRAL AXIS OF SAID HUB IS COAXIAL WITH SAID CENTRAL AXIS OF SAID DIE CAVITY; SURROUNDING THE OUTSIDE HUB WITH METAL PARTICLES BY FILLING SAID DIE CAVITY WITH METAL PARTICLES CONSISTING ESSENTIALLY OF COBALT AND AT LEAST ONE RARE EARTH METAL; ESTABLISHING A MAGNETIC FIELD THROUGH THE CONTENTS OF SAID DIE CAVITY, SAID MAGNETIC FIELD RADIALLY ORIENTED WITH RESPECT TO THE CENTRAL AXIS OF SAID DIE CAVITY; APPLYING PRESSURE TO THE CONTENTS OF SAID DIE CAVITY TO COMPACT SAID METAL PARTICLES INTO A SOLID ONE-PIECE ANNULAR MEMBER; AND APPLYING SUFFICIENT HEAT TO SINTER SAID METAL PARTICLES TO THE COATED HUB, THEREBY FORMING AN INTEGRAL ROTOR ASSEMBLY.

Claim 3

Dependent Claim 26 words

The process for making the integral rotor assembly as described in claim 1 wherein the metal oxide coating is applied by the process known as sputtering.

Claim 4

Dependent Claim 33 words

The process for making an integral rotor assembly as recited in claim 1 wherein the step of coating said hub with a metal oxide is accomplished by the method known as flame spraying.

Claim 5

Dependent Claim 28 words

The process for making an integral rotor assembly as recited in claim 1 wherein the coating of said hub with a metal oxide is applied by vapor deposition.

Claim 6

Dependent Claim 37 words

The process for making an integral rotor assembly as recited in claim 1 wherein the coating of inert material is selected from a group consisting of zirconium oxide, magnesium oxide, beryllium oxide, titanium oxide, and aluminum oxide.

Claim 7

Dependent Claim 36 words

The process for making a rotor assembly as recited in claim 2 wherein the coating of inert material is selected from a group consisting of zirconium oxide, aluminum oxide, magnesium oxide, calcium oxide and titanium oxide.

Claim 8

Dependent Claim 135 words

A process for making an integral permanent magnet generator rotor assembly comprised of a ferromagnetic hub and a ring-shaped rare earth and cobalt alloy magnet, said process comprising: sputter coating a ceramic material on the surface of said hub; placing said hub coaxially within an annular mold having a central axis; filling said mold around said hub with a powdered metal consisting essentially of cobalt and at least one rare earth metal; subjecting the contents of the mold to a magnetic field radially oriented with respect to the central axis of said mold; applying pressure to the contents of said mold to compact said metallic powder into a solid one-piece annular member around said hub; and sintering said powdered metal to form the coated hub and the sintered metal member into an integral rotor assembly.

Claim 9

Dependent Claim 135 words

A process for making an integral permanent magnet generator rotor assembly comprised of a ferromagnetic hub and a ring-shaped rare earth and cobalt alloy magnet, said process comprising: sputter coating a ceramic material on the surface of said hub; placing said hub coaxially within an annular mold having a central axis; filling said mold around said hub with a powdered metal consisting essentially of cobalt and at least one rare earth metal; subjecting the contents of the mold to a magnetic field radially oriented with respect to the central axis of said mold; applying pressure to the contents of said mold to compact said metallic powder into a solid one-piece annular member around said hub; and sintering said powdered metal to form the coated hub and the sintered metal member into an integral rotor assembly.

Claim 10

Dependent Claim 36 words

The process for making an integral rotor assembly as recited in claim 7 wherein the ceramic coating is selected from a group consisting of the zirconium oxide, magnesium oxide, beryllium oxide, titanium oxide, and aluminum oxide.

Claim 11

Dependent Claim 34 words

The process for making a rotor assembly as recited in claim 7 wherein the ceramic coating is selected from a group consisting of zirconium oxide, aluminum oxide, magnesium oxide, calcium oxide and titanium oxide.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1978-01-06	1978-07-08	1979-01-07	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1982-01-06	1982-07-08	1983-01-07	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1986-01-06	1986-07-08	1987-01-07	$7700.00	Window Closed / Lapsed

Process for making a rotor assembly

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