A field magnet manufacturing method where a bonded magnet's inner surface press-fitted in a yoke has a certain accuracy irrespective of the accuracy of the yoke's outer circumferential surface. A cylindrical bonded magnet from binding magnet particles with a thermosetting resin is fixed in a tubular yoke of magnetic material. The method includes reheating and softening the bonded magnet after thermal curing; and press-fitting in the bonded magnet after the softening step from a tapered portion on one end side of the yoke to press the bonded magnet's outer circumferential surface against the yoke's inner surface. The press-fitting includes feeding the bonded magnet relatively into the yoke while allowing a relative posture variation between the bonded magnet and the yoke so the bonded magnet's inner surface to be remolded into a shape along the inner surface of the yoke exhibits almost the same accuracy as the yoke's inner surface.

A gear housing for an epicyclic gear set, the gear housing including a hollow wheel having internal teething and a first front end with a first front-side joining surface; a housing cover having a second front end with a second front-side joining surface for longitudinally axially covering the hollow wheel; and a bonded connection for connecting the first front end to the second front end through the mating of the first and second front-side joining surfaces, at which the hollow wheel and the housing cover are connected to each other by a bonded connection, in particular, by heated tool welding, infrared welding, ultrasonic welding, or rotary friction welding.

Disclosed is an anhydride-free insulation system for current-carrying construction parts of an electric engine which comprises:

(A) a mica paper or mica tape for wrapping parts of said electric engine that are potentially current-carrying during operation of the engine, which mica paper or mica tape is impregnable via vacuum pressure impregnation with a thermally curable epoxy resin formulation and comprises one or more thermally activatable sulfonium salt initiators for the homopolymerisation of the epoxy resins present in said said thermally curable epoxy resin formulation or a mixture thereof in an amount sufficient to homopolymerize the epoxy resin taken up by the mica paper or mica tape and the construction part of the engine during the vacuum pressure impregnation step;
(B) a thermally curable bath formulation for the vacuum pressure impregnation comprising (i) a polyglycidyl ether or a mixture thereof, and (ii) a cycloaliphatic epoxy resin comprising at least two epoxy groups, which are fused to a cycloaliphatic ring, or a mixture thereof,
which formulation is substantially or, preferably, entirely free of thermally activatable curing initiators for the epoxy resin formulation.

A gas-permeable porous fluororesin membrane (4) made of a fluororesin is welded to a resin component (2) made of a thermoplastic resin using a welding horn (62) having a working surface (62p) adapted to be brought into contact with a work object and provided with a projection (62t). The working surface (62p) of the welding horn (62) is provided with, for example, a plurality of projections (62t). The plurality of projections (62t) may be arranged in a grid pattern on the working surface (62p).

A rotor includes a yoke that is formed annularly and a resin magnet integrated with the yoke. The yoke includes a first inner circumferential surface, a second inner circumferential surface, and a third inner circumferential surface. The second inner circumferential surface is adjacent to the first inner circumferential surface, and has a radius larger than a radius of the first inner circumferential surface. The third inner circumferential surface is adjacent to the second inner circumferential surface, and has a radius larger than both of the radius of the first inner circumferential surface and the radius of the second inner circumferential surface.

Methods of joining components to form vehicle assemblies, such as engine assemblies, are provided. The methods include arranging a first component having a first channel defined therein in a mold, arranging a second component having a second channel defined therein in the mold, and aligning the first and second channel to define a pin-receiving channel. At least one polymeric composite pin is inserted into the pin-receiving channel thereby joining the first and second components, wherein an adhesive is disposed adjacent to at least a portion of the polymeric composite pin.

A producing method for a cylinder block includes: a spraying step of spraying a metallic material onto a bore inner surface of at least one cylinder bore formed in the cylinder block to form a spray deposit thereon; a pressurizing step of applying a predetermined pressure onto a surface of the spray deposit formed on the bore inner surface in the spraying step; and a honing step of applying a honing processing to the surface of the spray deposit after the pressurizing step.

A motor assembly tool includes a stator defining a plurality of slots and a varnish application fixture. The fixture includes a disc defining a plurality of slots, an outer shield disposed on the disc radially outward of the slots of the disc, and an inner shield disposed on the disc radially inward of the slots on the disc. The disc is disposed on the stator and the outer and inner shields are configured to direct varnish through the slots of the disc and into the slots of the stator.

A method is provided for manufacturing. During this method, a first woven fiber sleeve is disposed over a first mandrel to provide a first overbraided mandrel. The first woven fiber sleeve is wrapped circumferentially around the first mandrel. An opening is formed through a side of the first woven fiber sleeve. A second woven fiber sleeve is disposed over a second mandrel to provide a second overbraided mandrel. The second woven fiber sleeve is wrapped circumferentially around the second mandrel. The second overbraided mandrel is arranged with the first overbraided mandrel. The second woven fiber sleeve engages the side of the first woven fiber sleeve. A second overbraid first end is disposed at and extends circumferentially around the opening. A polymer material is disposed with the first woven fiber sleeve and the second woven fiber sleeve to provide a duct structure.

An apparatus or assembly for forming injection molded magnets in permanent magnet rotors or laminations for such rotors. The assembly includes a plurality of platens defining an axial boundary of a die cavity and a plurality of support shoes that are radially moveable between a closed position defining a radial boundary of the die cavity, and an open position creating a gap between the rotor core and the plurality of support shoes. The assembly has an injection system for filling at least one of the plurality of voids of the rotor core with a magnetic slurry, and a plurality of alignment magnets configured to magnetically align the magnetic slurry.