Rotor assembly and method of making

Abstract

A rotor assembly is provided in which the rotor assembly comprises includes a first core portion, wherein the first core portion has at least one first core protrusion, and a second core portion, wherein the second core portion has at least one second core protrusion. The first core portion and the second core portion are configured to be matingly coupled to each other so as to form an assembled rotor assembly. In addition, the rotor assembly comprises includes a plurality number of magnetizable members wherein respective ones of the plurality of magnetizable members are coupled to each of the first core protrusions and coupled to each of the second core protrusions. The plurality of magnetizable members are adapted to be coupled to a magnetizing fixture prior to mating the first and second core portions so as to magnetize the magnetizable members.

In the claims:  
     
         1 . (Currently amended) A rotor assembly comprising: 
 a first core portion, said first core portion having at least one first core protrusion;    a second core portion, said second core portion having at least one second core protrusion,    wherein said first core portion and said second core portion are configured to be matingly coupled to each other so as to form said rotor assembly; and    a plurality of magnetizable members wherein respective ones of said plurality of magnetizable members are coupled to each of said first core protrusions and coupled to each of said second core protrusions,    wherein said plurality of magnetizable members are adapted to be coupled to a magnetizing fixture, while being coupled to respective ones of said first and second core protrusions and prior to mating said first and second core portions so as to magnetize said magnetizable members.    
     
     
         2 . (Original) The assembly rotor of  claim 1 , wherein said first core portion and said second core portion comprise a composite ferrous material.  
     
     
         3 . (Original) The rotor assembly of  claim 1 , wherein said first core portion and said second core portion are coupled by a connecting member selected from the group consisting of a shaft, pin and adhesive.  
     
     
         4 . (Currently amended) The rotor assembly of  claim 1 , wherein each of said plurality of magnetizable members comprise comprises a magnet selected from the group consisting of bonded magnets, sintered magnets and cast magnets.  
     
     
         5 . (Original) The rotor assembly of  claim 4 , wherein said bonded magnets comprise a powder embedded in a polymer matrix wherein said powder comprises a neodymium-iron-boron alloy.  
     
     
         6 . (Original) The rotor assembly of  claim 1 , wherein said respective ones of said plurality of magnetizable members are overmolded to each of said first core protrusions and overmolded to each of said second core protrusions.  
     
     
         7 . (Original) The rotor assembly of  claim 1 , wherein said first core protrusion and said second core protrusion are skewed protrusions.  
     
     
         8 . (Original) The rotor assembly of  claim 7 , wherein said magnetizing fixture comprises a plurality of laminations, said magnetizing fixture having a magnetizing surface being skewed to match a surface of each of said skewed protrusions.  
     
     
         9 . (Original) The rotor assembly of  claim 1 , wherein said magnetizing fixture comprises a magnetizing surface adapted for being disposed over the entirety of said respective ones of said plurality of magnetizable members and wherein said magnetizing fixture comprises a wedge so as to allow a magnetizing field therethrough.  
     
     
         10 . (Original) The rotor assembly of  claim 1 , wherein said rotor assembly is disposed in a shell.  
     
     
         11 . (Currently amended) A rotor assembly comprising: 
 a first core portion, said first core portion having a first skewed core protrusion;    a second core portion, said second core portion having a second skewed core protrusion,    wherein said first core portion and said second core portion are configured to be matingly coupled to each other so as to form said rotor assembly; and    a plurality of magnetizable members wherein respective ones of said plurality of magnetizable members are coupled to each of said first skewed core protrusions and coupled to each of said second skewed core protrusions,    wherein said plurality of magnetizable members are adapted to be coupled to a magnetizing fixture, while being coupled to respective ones of said first and second core protrusions and prior to mating said first and second core portions so as to magnetize said magnetizable members.    
     
     
         12 . (Original) The rotor assembly of  claim 11 , wherein said first core portion and said second core portion comprise a composite ferrous material.  
     
     
         13 . (Original) The rotor assembly of  claim 11 , wherein said first core portion and said second core portion are coupled by a connecting member selected from the group consisting of a shaft, pin and adhesive.  
     
     
         14 . (Currently amended) The rotor assembly of  claim 11 , wherein each of said plurality of magnetizable members comprise comprises a magnet selected from the group consisting of bonded magnets, sintered magnets and cast magnets.  
     
     
         15 . (Original) The rotor assembly of  claim 14 , wherein said bonded magnets comprise a powder embedded in a polymer matrix wherein said powder comprises a neodymium-iron-boron alloy.  
     
     
         16 . (Original) The rotor assembly of  claim 11 , wherein each of said respective ones of said plurality of magnetizable members are overmolded to each of said first skewed core protrusions and overmolded to each of said second skewed core protrusions.  
     
     
         17 . (Original) The rotor assembly of  claim 11 , wherein said magnetizing fixture comprises a plurality of laminations, said magnetizing fixture having a magnetizing surface being skewed to match a surface of each of said first and second skewed core protrusions.  
     
     
         18 . (Original) The rotor assembly of  claim 11 , wherein said magnetizing fixture comprises a magnetizing surface adapted for being disposed over the entirety of said respective ones of said plurality of magnetizable members and wherein said magnetizing fixture comprises a wedge so as to allow a magnetizing field therethrough.  
     
     
         19 . (Original) The rotor assembly of  claim 11 , wherein said rotor assembly is disposed in a shell.  
     
     
         20 - 27 . (Cancelled)