Innovative Bonding and Spray-Forming Techniques for Cost-Effectively Producing High Performance Induction Motors

Award Information
Agency: Department of Energy
Branch: N/A
Contract: DE-FG02-96ER82271
Agency Tracking Number: 34633
Amount: $74,607.00
Phase: Phase I
Program: SBIR
Awards Year: 1996
Solicitation Year: N/A
Solicitation Topic Code: N/A
Solicitation Number: N/A
Small Business Information
161 First Street, Cambridge, MA, 02142
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Mr. James O'Rourke
 (617) 349-0948
Business Contact
 Mr. Steven St. Germain
Title: Manager
Phone: (617) 349-0914
Research Institution
40816 November 13, 1996 SatCon Technology Corporation While cost-effective, high performance electric motors are crucial to the success of any electric or hybrid-electric vehicle program, their manufacturability is the primary impediment to their development. This project will decrease manufacturing costs by developing new fabrication techniques for rotor assemblies and thinly laminated stator stacks. The rotor assembly concept involves using an innovative bonding technique to assemble a net-shape copper squirrel cage to a net-shape magnetic core. The laminated stack concept involves using an advanced spray-forming process to fabricate cores of arbitrarily thin laminations in a one-step process. Phase I will demonstrate the feasibility of using these techniques to make electric motors with a performance-to-cost ratio that will make them economically viable, thus bringing electric automobiles another step closer to reality. Anticipated Results/Potential Commercial Applications as described by the awardee: Most applications that use rotating machinery or require high power-to-weight ratios can enjoy an efficiency improvement through higher rotational speeds. Electric vehicles and next-generation high-speed turbo machines (e.g., HVAC compressors) are the nearest-term and largest market applications for cost-effective, high-performance electric motors.

* Information listed above is at the time of submission. *

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