A dual-rotor machine comprising a dual rotor support structure rotatably connected to a frame. A stationary stator is disposed between the rotors and is fixed to the frame. An inner rotor and outer rotor, each comprising a permanent magnet Halbach array, are coaxially disposed with the stator and are rotable about the stator. In this configuration, the inner rotor channels its magnetic flux to its outside, while the outer rotor channels its magnetic flux to its inside. The magnetic flux density at the stator for the dual-rotor machine can be as high as 2 Tesla or higher for high-grade neodymium-iron-boron permanent magnet material, and the stored magnetic energy for conversion to mechanical or electrical energy available to the stator may be at least 0.5 KJ/m. The rotor Halbach arrays may comprise monolithic permanent magnets with continuously variable magnetic field direction.

A flux directed magnet and a method of manufacturing a flux-directed magnet in a reduced number of process steps is described and claimed. The present invention is, in an embodiment, a single-step manufacturing of flux directed magnet assemblies such as, but not limited to, Halbach arrays of arbitrary multipole order. Even tube-shaped flux directed magnet assemblies such as Halbach arrays with large aspect ratio, i.e. length to diameter, can be produced in single steps using the method of the invention. Alternatively, the present invention may be one step of a plurality of steps in a process for manufacturing of flux directed magnet assemblies.

Rotors for electrical machines and methods of fabricating the same are disclosed. Electrical machine rotors may include a hollow non-magnetic shaft, an active region, and a plurality of coolant passages extending within the active region. The hollow non-magnetic shaft may extend along an axis and have an exterior surface that defines a shaft space extending along the axis. At least a portion of the active region may be disposed within the shaft space.

An electric motor including a coil assembly having a plurality of coils which may be arranged in the shape of a cylinder. The motor further includes a rotor including a plurality of outer magnets configured as a first Halbach cylinder surrounding the coil assembly. An outer magnet housing of the rotor is coupled to and surrounds the plurality of outer magnets. A plurality of inner magnets are arranged as a second Halbach cylinder with the coil assembly being interposed between the plurality of inner magnets and the plurality of outer magnets. An inner magnet housing is coupled to the plurality of inner magnets and surrounds an output shaft.

A gas compressor includes an incompressible fluid source for storing an incompressible fluid. A rotary shaft is coupled to the incompressible fluid source. Operation of the rotary shaft draws the incompressible fluid up or down the rotary shaft. A piston chamber is coupled to each piston in a set of pistons. The incompressible fluid is delivered to the first piston by a controlled fluid valve assembly, to drive the first piston. The centripetal force from the rotation of the rotary shaft and the force of incompressible fluid from an impeller drive the first piston to compress a gas in the piston chamber of the first piston. The incompressible fluid is released from the first piston, by the controlled fluid valve assembly. The incompressible fluid is alternately delivered to the second piston to drive the second piston and compress gas.

A gas compressor includes an incompressible fluid source for storing an incompressible fluid. A rotary shaft is coupled to the incompressible fluid source. Operation of the rotary shaft draws the incompressible fluid up or down the rotary shaft. A piston chamber is coupled to each piston in a set of pistons. The incompressible fluid is delivered to the first piston by a controlled fluid valve assembly, to drive the first piston. The centripetal force from the rotation of the rotary shaft and the force of incompressible fluid from an impeller drive the first piston to compress a gas in the piston chamber of the first piston. The incompressible fluid is released from the first piston, by the controlled fluid valve assembly. The incompressible fluid is alternately delivered to the second piston to drive the second piston and compress gas.

Motors disclosed herein may include a stator comprising electrical windings thereon. A stator housing at least partially houses the stator. A rotor assembly is rotatingly coupled with the stator housing and includes a rotor, which may be formed of a polymer, and a plurality of magnets coupled with the rotor. In implementations the magnets are coupled with the rotor using a friction fit or one or more snap locks, and/or without the use of glue. In implementations the rotor assembly excludes a back-iron. In implementations the stator housing is formed of a polymer. Methods of formation of a rotor are disclosed, including methods of inserting one or more magnets into slots within the rotor, including at varying angles of rotation. In implementations the magnets are organized into a Halbach array.

Motors disclosed herein may include a stator comprising electrical windings thereon. A stator housing at least partially houses the stator. A rotor assembly is rotatingly coupled with the stator housing and includes a rotor, which may be formed of a polymer, and a plurality of magnets coupled with the rotor. In implementations the magnets are coupled with the rotor using a friction fit or one or more snap locks, and/or without the use of glue. In implementations the rotor assembly excludes a back-iron. In implementations the stator housing is formed of a polymer. Methods of formation of a rotor are disclosed, including methods of inserting one or more magnets into slots within the rotor, including at varying angles of rotation. In implementations the magnets are organized into a Halbach array.

A magnetization method capable of magnetizing a magnetic material in such a manner that the magnetic material produces a magnetic orientation in a direction inclined from a predetermined direction is provided. A magnetization method includes: a step of arranging a plurality of magnetic material pieces so that they includes a magnetic material piece that can produce a magnetic orientation in a direction inclined from a predetermined direction; a first magnetization step of magnetizing a magnetic material piece disposed between the first and second magnetization parts that form a magnetic path through the magnetic material piece that can produce the magnetic orientation in the direction inclined from the second direction; and a second magnetization step of magnetizing the magnetic material piece that can produce the magnetic orientation in the predetermined direction.

A magnetization method capable of magnetizing a magnetic material in such a manner that the magnetic material produces a magnetic orientation in a direction inclined from a predetermined direction is provided. A magnetization method includes: a step of arranging a plurality of magnetic material pieces so that they includes a magnetic material piece that can produce a magnetic orientation in a direction inclined from a predetermined direction; a first magnetization step of magnetizing a magnetic material piece disposed between the first and second magnetization parts that form a magnetic path through the magnetic material piece that can produce the magnetic orientation in the direction inclined from the second direction; and a second magnetization step of magnetizing the magnetic material piece that can produce the magnetic orientation in the predetermined direction.