WO2019113165A1

WO2019113165A1 - Molded self-assembled electromagnet motors and devices

Info

Publication number: WO2019113165A1
Application number: PCT/US2018/064003
Authority: WO
Inventors: Galen J. Suppes
Original assignee: The Suppes Family Trust
Priority date: 2017-12-06
Filing date: 2018-12-05
Publication date: 2019-06-13

Abstract

Electromagnetic devices are made by a molding method comprising use of magnetic fields to place paramagnetic powders into optimal core configurations. The optimal configurations are set in place by the curing of a continuous solid-forming mixture that surrounds the particles. An example system uses urethane monomers to set iron powder mixtures into an inner and outer core of an electromagnetic coil.

Description

MOLDED SELF-ASSEMBLED ELECTROMAGNET MOTORS AND DEVICES

CROSS REFERENCE TO RELATED APPLICATIONS

[1] This application is a continuation -in-part of Provisional Applications Ser. No 62/595,322 filed Dec. 6, 2017 entitled "Electric Motor Related Inventions", Ser. No 62/613,851 filed Jan. 5, 2018 entitled " Electric Motor Related Inventions ", Ser. No 62/658,129 filed Apr. 16, 2018 entitled "Tethered-Glider Related Inventions", Ser. No. 62/678,147 filed May 30, 2018 entitled " Tethered-Glider Related Inventions ", Ser. No. 62/694,178 filed Jul. 5, 2018 entitled " Tethered-Glider Related Inventions", and Ser. No. 62/748,406 filed Oct. 20, 2018 entitled "Electric Motor and Electromagnetic Device Related Inventions". All of the above-listed applications are incorporated by reference in their entirety herein.

FIELD

[2] The present invention relates to electromagnet devices. More specifically this invention relates to a method of making electromagnet devices using a molding method with self-assembling cores and the devices made by this method.

BACKGROUND

[3] Molded self-assembled electromagnetic devices can transform society by enabling both lower-cost and improved-performance devices. Improved performance includes lower weight and smaller volume. This includes devices like motors, transformers, NMR/MRI medical devices, DC-DC converters, cyclotrons, nuclear accelerators, and electronic brakes, aircraft, automobiles, and trains.

[4] The process of this invention is a method to form cores of electromagnets.

Traditional methods of making cores includes gluing laminated (stamped) plates or fabricating solid metal cores. [5] For purposes herein, the core is often referred to as an inner core (e.g. a rod inside a toroidal coil) and an outer core (e.g. a cylindrical shell outside a toroidal coil). Molded cores allow for greater complexity in designs. Greater complexity allows for improved heat transfer options.

[6] Molded cores allow for use of a range of materials in the mold. Solid metal rods may be used. Other solid materials may be used such as soft iron, laminated silicon steel, lamination, silicon alloying, special alloys, and vitreous metal. Power materials may be used. Example powder materials include iron, carbonyl iron, hydrogen-reduced iron, MPP

(molypermalloy), Supermendur, high -flux (Ni-Fe), sendust, KoolMU, nanocrystalline,

[7] This invention has applications with flying vehicles. Prominent groups acknowledge that Bernoulli's equation does not accurately describe lift in air. Likewise the momentum theory of lift is also incomplete. A complete theory first has a theorem of: equilibrium flight occurs for an object when that object bends/accelerates air downward such that the net

[mass]X[acceleration] of air is equal to the weight of the object. Next, analytical geometry dictates: for an object to achieve high L:D ratios, the pressures generated from the downward bending/acceleration of air must be transferred to the object on surfaces of low pitch;

preferably a surface pitch of -1 to 3° (to which is added an angle of attack such as 1° during flight).

LIST OF FIGURES

[8] Fig. 1. Stacked rotary (right) induction motor as compared to regular induction motor.

[9] Fig. 2. Expanded view of coils of induction motor with two co-centric reactive surface tubes.

[10] Fig. 3. Illustration of short stator engaged with armature rail as part of monorail with emphasis on illustrating electromagnets on opposite sides of monorail armature. [11] Fig. 4. Illustration of Fig. 3 expanded to show how repulsive forces generated by the electromagnets impact U-shaped short stator cross section with emphasis on top of U-shape which acts as a very stiff flexible joint. Illustration does not show optional electromagnets above monorail or complex coils that bend over much of monorail surface.

[12] Fig. 5. Illustration of Fig. 4 expanded to illustrate where an electromagnet device could be inserted to convert the inherent joint area into a joint area with a controllable stiffness.

[13] Fig. 6. A control joint comprised of a helical electromagnet around a longitudinal core of solid core components separated by flexible solid material.

[14] Fig. 7. Illustration of coil with heat transfer cavity in between wires of the coil.

[15] Fig. 8. Illustration of switching method using short stator. Indicated are: A) non switch chassis position and non-switch guideway location, B) non-switch chassis position and switch guideway location, C) switch chassis position and non-switch guideway location, and D) switch chassis position and switch guideway location.

[16] Fig. 9. Illustration of slant angle defined for cross section at constant longitudinal position for an aircraft at zero degrees of roll.

[17] Fig. 10. Example wide-body fuselages design with center seating section and intermittent tensile supports connecting upper platform to lower platform.

INVENTION SUMMARY AND DETAILED DESCRIPTION

Molding

[18] For the molded electromagnet devices of this invention, the following are placed in the mold along with a solid-forming liquid (or paste): electromagnet coils and paramagnetic solids or particles. Hereafter in this invention description: 1) the term "liquid" refers to a material having a consistency between that of a paste to that of a free-flowing liquid and 2) the term "ferro-objects" refers to paramagnetic materials of size or shape from that of a small particle to that of a larger solid object like a rod.

[19] A solid is formed from the liquid that is placed in a mold. The ferro-objects form the core of the electromagnet device.

[20] Examples of solids that are formed are: thermoset polymers, other polymers, ceramics, and porcelain. The many materials known to form solids from liquids may be used in this invention. Example materials to form thermoset polymers are isocyanates, polyols, epoxy resins, and phenolic resins.

Novel Self Assembly

[21] During molding, a self-assembly process assembles an improved electromagnet core relative to a core of random ferro-objects. An electric current is applied to the coil in the mold. The current energizes coil and forms a magnetic field. The ferro-objects move to improved positions, forming an improved core, in response to the magnetic field.

[22] As part of the process, the solid-forming liquid: 1) surrounds at least part of the coils and ferro-objects and 2) forms a solid. These two steps form a solid structure with the ferro- objects set in the improved positions.

[23] Optionally, the solid-forming liquid forms the outer surface of the device.

Mold Options for Enhanced Self Assembly

[24] External magnetic coils may be used in combination with coils in the mold to form stronger magnetic fields of the desired shape. Typically, these external coils are placed pole- to-pole with the internal coils; this is referred to as being coupled with the internal coils. When energized, an external coil is a magnet. Energize indicates a voltage is applied. The term "voltage applied" indicates the coil is in a circuit and current flows through the coils. [25] Optionally, paramagnetic or electrically-conductive materials outside the mold may be used to influence the magnetic field in the mold. A skin (or shell) may be placed along the inner surface of the mold; this skin would become an outer surface of the cast.

[26] Inserts may be placed in the core to: a) enhance heat transfer, b) improve strength, c) assist formation of improved Eddy currents, d) provide monitoring capabilities, and e) provide control capabilities.

[27] The following are examples of inserts to enhance heat transfer: a) a fin that extends into and out of the cast (i.e. device being molded), b) a duct passing through the cast with an entry and an exit at the surface of the cast, c) a removable insert that has an entry and an exit at the surface of the cast, and d) a thermally-conductive skin. An example of a removable insert is an insert that melts or dissolves (e.g. water soluble filament) at conditions not harmful to the cast.

[28] Non-inclusive examples of ferro-objects includes ferromagnetic particles and short sections of ferromagnetic rods.

[29] The ferro-objects may be (but are not limited to) powders of iron, carbonyl iron, hydrogen-reduced iron, MPP (molypermalloy), Supermendur, High-flux (Ni-Fe), Sendust, KoolMU, or nanocrystalline. Powders are comprised of particles. The largest dimension of the particles are preferably between 10 nm and 0.2 mm; and more-preferably between 50 nm and 50,000 nm.

[30] These ferro-objects form a composite with the solid-form liquid. Methods known in the art and science can be used to advantage to improve the strength of the composites and to create a higher packing of ferro-objects in the core that is formed. By example, a large solid object of out perimeter similar to that of the inner core surface may be placed inside a coil in the mold with powders filling the gaps between between the object's outer perimeter and in the inner core surface. [31] Multiple rod sections may be used as ferro-objects. The rods, or other objects, may be placed end-to-end to form a long inner core.

[32] When powders are placed in a mold prior to placing the solid-forming liquid into the mold, it is preferred to place the contents of the mold under vacuum prior to introducing the solid-forming mixture. The vacuum reduces amount of powder that is not wetted with the solid-forming liquid in the cast that is formed.

[33] For powders in a solid-forming liquid, a flowing mixture at 20%-60%by volume (more preferably 30%-50%) can be influenced under magnetic fields to form higher densities up to 60%-90% (more preferably 65%-85%) by volume. Preferably, the magnetic fields form the higher densities in the inner core.

[34] More-expensive higher-saturation flux powders may be placed in magnetic field bottleneck areas with less expensive materials used in other core volumes. Here, saturation flux is magnetic saturation flux.

[35] Powders may be introduced to the mold after higher-densities are formed. This allows for the final cast's powder content to be higher than what readily flows in a mixture of power and solid-forming liquid.

[36] It is preferred to mold/glue wires of the coil into a shape prior to placing in a the mold. This allows for more-complex coil designs and can reduce the difficulty of the molding process.

A Preferred Molding Method

[37] A preferred molding method is a method for fabricating an electromagnetic device comprising: placing at least one insulated wire coil in a mold, placing a solid-forming liquid in the mold, placing a plurality of solid particles in the mold said solid particles having saturation fluxes greater than 0.5 Tesla, applying voltage to said wire coil; wherein the coil forms a magnetic field said magnetic field changes the solid particle positions forming volumes of increased solid particle concentrations (overall densities) and wherein the solid- forming liquid forms a solid.

[38] The method preferably forms an electromagnetic device with an inner core and an outer core.

[39] Optional enhancements of this preferred method include: placing a solid magnetic core within the wire coil, placing a paramagnetic object having at least one dimension greater than 1.0 mm in the position of an inner core of the wire coil, placing a duct-forming insert in the mold, placing a rotating device in the mold said rotating device is coated with a removable coating, and placing a magnet outside the mold that is pole-to-pole with the inner core to be formed in the mold.

[40] An example of a solid magnetic core is a paramagnetic object having at least one dimension greater than 1.0 mm.

[41] More-specific embodiments of the method are wherein: the solid-forming liquid is a mixture of monomers and the solid is a polymer, the solid-forming liquid is a mud and the solid is a ceramic, said insulated wire coils is comprised of wire with an outer thermoplastic coating, the device is a joint flexible in directions lateral to longitudinal dimension of the pole and increased current in a coil surrounding the pole increases stiffness of the joint, the solid particles are mixed with the polymer-forming liquid prior to placing in the mold, additional solid particles are placed in the mold after volumes of increased solid particle density are formed, the polymer-forming liquid forms a thermoset polymer, materials of high magnetic interaction are placed outside the cast volume of the mold, the high magnetic interaction materials are paramagnetic, the high magnetic interaction materials are ferromagnetic, and the high magnetic interaction materials are electrically conductive and the magnetic field is of varying polarity. [42] Optionally, during the formation of the core, the liquid may be circulated. The entire mold may be oscillated or turned so as to move the paramagnetic particles such that the particles may position then stay in optimal positions. Sonic waves can also assist movement of particles.

[43] It is preferred to mold the coils into shape before inserting into the mold/cast; this shaping can be assisted by having a thermoplastic coating around a more-fixed insulator where pressure and/or heating is sufficient for adjacent wires to set when in contact.

A Preferred Molded Device

[44] A preferred molded device is a molded electromagnetic device comprised of: an exterior wall, a continuous polymer phase said polymer phase comprising a thermoset polymer surrounding a plurality of particles having saturation fluxes greater than 0.5 Tesla; wherein the thermoset polymer and particles form a solid composite electromagnet core said core have a plurality of regions of different average densities and wherein a first region of highest average density is an inner core (inside the coil), a second region of lower average density is in the outer core and adjacent to the coil (outside the coil at a region of lower radius than median outer core radius), and a third region of lowest average density is outside the coil and further distant from the coil than the second region of lower average density (is the outer core at region of greater radius than median radius).

[45] More specifically, the first region has a saturation flux greater than 0.5; and more preferably between 0.8 and 2.5. The outer core region adjacent to the coils (second region) has a average saturation flux between about 0.2 and 2.5 and more preferably between 0.3 and 1.2, and this average is at least in part comprised of a mixture of ferro-objects having saturation fluxes between 0.5 and 2.5 with maximum dimensions less than 1 mm surrounded by a continuous solid phase having saturation fluxes less than 0.4. The third region has a average saturation flux between about 0.2 and 1.5 and more preferably between 0.2 and 0.8, and this average is at least in part comprised of a mixture of ferro-objects having saturation fluxes between 0.5 and 2.5 with maximum dimensions less than 1 mm surrounded by a continuous solid phase having saturation fluxes less than 0.4.

[46] Here, the radius is from a longitudinal center axis of the inner core. In the case of a long toroidal electromagnet, the longitudinal axis is the center line of the inner pole of the electromagnet.

[47] Unless otherwise specified, the longitudinal axis/dimension is a line of symmetry that best approximates the line around which the coils of the electromagnet are wound.

[48] Optional enhancements of the device of the preferred device include: the third region of lowest particle density forms the outer wall of the electromagnetic device; and said electromagnetic device further comprised of a first set of coils, a second set of coils, and a cooling fluid duct between the first set and second set of coils.

A Rotary Motor Molded Device

[49] The molded device may be a rotary electric motor which is an electromagnetic device comprised of an armature said armature having an axis of rotation, said armature having a sequence of magnetically interactive shells radially spaced from the axis of rotation, a stator said stator having a sequence of wire coils. In this configuration, electromagnets located between adjacent cylindrically-shaped conductive shells would add to forces on at least two shells.

[50] Here, the "shells" are hollow cylinders; preferably electrically conductive shells that are reactive surfaces of an induction motor. Preferably, these shells are laminated with planes of insulation extending radially.

[51] This embodiment is on electric induction motors that use the following technologies: a) injection molded stators with self-assembling electromagnet cores for complex yet low- cost electromagnet fabrication, b) stacked cylinder electromagnets that utilize both poles of electromagnets on separate aluminum cylinders and c) direct contact air cooling of both sides of the electromagnets. Fig. 1 compares a conventional induction motor to the stacked rotary induction motor.

[52] A conventional rotary induction motor as one reaction surface armature 1 that is a cylinder (shell), stator electromagnets 2, and a stator core. The stacked rotary motor has an outer 4 and inner 5 reaction surface armatures and electromagnets 6 with cores 7 between the co-centric cylinders. An expanded view if the cores 7 (Fig. 2) of the stacked rotary induction motor reveals a partial horseshoe shape and an air gap 8 between the coils for cooling.

[53] The stacked rotary induction motor places the electromagnets/cores/stator between rotors that rotate on a common shaft emerging from one end of the motor. In this design: both ends of the coils are in contact the air gap next to rotors making enhanced heat removal possible when a cooling fluid is circulated in this space, many coils engage two rotor armatures, it is preferred to have cores of a partial horseshoe configuration, and the stator is secured to be stationary while the rotors rotate. .

A Linear Motor Molded Device

[54] A molded device may be a linear motor, the linear motor comprising: a short stator said stator having longitudinal sections of a front fifth, middle fifth, and rear fifth; a longitudinally extending armature said armature having a lateral width, a vertical height, a first side and a second side said second side opposite the first side, a first series of stator electromagnets said first series exerting a lateral force on the first side of the armature, a second series of stator electromagnets said second series exerting a lateral force on the second side of the armature (or second armature parallel to the first armature), a front average separation distance said front average separation distance being an average of distances separating the first series (of magnets) from the second series located in the front fifth of the short stator, a middle average separation distance said middle average separation distance being an average of distances separating the first series from the second series located in the middle fifth of the short stator, wherein the front average separation distance is at least twenty percent greater than the middle average separation distance.

[55] The preferred armature is a monorail of a transit system.

[56] Optional enhancements of the linear motor include: a means of measuring the clearance gap between a point on the front fifth of the stator, a means of changing the force on the short stator in the direction of the closest point on the armature rail to the short stator, and a control means which inputs the clearance gap measurement and controls the force based on a control algorithm.

[57] Time-averaged clearance gaps for the middle fifth the linear motor are preferably between 1 and 8 mm and more preferably between 2 and 5 mm.

[58] Fig. 3 illustrates a U-shaped cross section of the preferred short stator where the stator has electromagnets on opposite sides of a monorail have reactive rail features, left coils 9 and right coils 10. The entire monorail 11 may be conductive or conductive strips 12 may be attached along the sides. If a conductive strip distributes grid electricity, it must be insulated from a path to the ground; and if one strip is a ground strip and the other a power strip, the two strips must be insulated from each other.

[59] Fig. 4 illustrates how repulsive forces on the pair of electromagnets translate to forces with lateral components (in addition to longitudinal)on the short stator y including a location on the top 13 of greatest stress that acts like a hinge to slight bending actions.

[60] Fig. 5 illustrates the location of a joint 14 where it is advantageous to be able to vary the stiffness of the joint; basically increased current in the coil of the joint increases stiffness and reduces the lateral separation of the pair of coils at a given lateral force between the pair of coils. This allows slight changes in clearance to be controlled independent of propulsion force. [61] A Solid State Control Joint Molded Device

[62] Fig. 6 is an example of a solid state control joint. The control joint comprised of a helical electromagnet 15 around a longitudinal inner core of solid core components 16 separated by flexible solid material 17. The solid core components are preferably ferro- objects that fit together in a manner that provides flexibility perpendicular to a longitudinal centerline of the longitudinal inner core. An outer core 18 reduce increase the strength of the magnetic field.

[63] A joint having controlled flexibility preferably comprises: a flexible electromagnet core said core having discrete paramagnetic sections separated by flexible sections along a longitudinal dimension of the core, a coil surrounding the flexible electromagnetic core; whereby increased current in the coil induces increased longitudinal attractive forces of the discrete paramagnetic sections resulting in greater resistance to core flexibility in at least one direction perpendicular to the longitudinal axis of the core.

[64] Optional enhancements of the joint of joint include: having flexible sections are a thermoset polymer, having a a pseudo line of pivoting movement resulting in the separation of magnets along opposite sides of an armature of a linear motor, having end-to-end adjacent paramagnetic sections have matching male and female geometries where the male geometry is of a shape between that of a ball and a cone, having discrete core sections have maximum dimensions greater than 0.01 mm and less than 300 mm, and having injection -molded flexible polymer separating solid paramagnetic sections as a solid-state joint.

[65] This joint may have the shape of a rod and can serve as a rod of variable stiffness for applications line supporting a wheel and serving as a shock absorber. The joint may be of the general configuration of a horseshoe electromagnet.

A Thin-Walled Tube As Coil Wire Molded Device [66] Molded construction is particularly useful for thin-walled materials to create additional strength. For copper, or other metal, tubes that serve as conductors for an electromagnet, the wall thickness tends to be much greater than needed for the current loading. A molded construction provides needed structural strength.

[67] A preferred thin-walled tube coil electromagnet is an electromagnet coil comprised of: a tube bent into a coil configuration said tube comprising a first end, a second end, and a fluid volume; insulation on the outer surface of the coil, a fluid entry port located on the first end and a fluid exit port on the second end, a plurality of electromagnetic core regions of different average densities, an electric circuit connection surface near the first end and a circuit-completing connection on the second end (basically, a means to connect the tube to a circuit to provide flow of electrons through the coil) wherein the tubes are surrounded by a continuous solid phase.

[68] Optional enhancements of the thin-walled tube coil electromagnet wherein: no insulation is on the tube with application in a high temperature application like an induction welder (the continuous solid phase may be a ceramic or porcelain), the tube is of a radial perimeter other than circular, the tube is generally of a rectangular radial perimeter, the average tube wall thickness is less than one third the average radial dimension of the tube volume, the average tube wall thickness is less than one tenth the average radial dimension of the tube volume, the average tube wall thickness is less than one twentieth the average radial dimension of the tube volume, the tube coils are substantially contained in a continuous polymer phase where said polymer phase increases structural strength relative to the tube coil without polymer phase wherein the polymer phase adheres to the outer surface of the tube coil (basically, the objective is to reduce the amount of copper in the wall to the extent possible so as to reduce weight and thin walls have insufficient structural strength for the application but boding of the walls into a larger essentially honeycomb -like structure provide structural strength), a honeycomb-like polymer structure of a continuous closed path of insulating material form an electromagnetic path wherein a conductive material is flowed through the structure coating the structure toward forming an electrically conductive layer, the composite of tube and polymer is 3D printed, the tube surfaces on at least part of the coil perimeter are bonded to the core, and the tube are connected to a fluid circulation means.

A Coil with Cooling Cavity Between Wires Molded Device

[69] A preferred efficiently cooled electromagnet coil is comprised of: insulated coil wires; a cooling cavity located between coil wires said cavity comprising a volume of fluid, an entry port, and an exit port; whereby a fluid flows through the entry port, the volume, and the exit port; and wherein said fluid removes heat from the coil wires.

[70] Optional enhancements of the coil with the cooling cavity are wherein: the coil wires are around an electromagnetic inner core, said cavity is generally annular in shape and the exit port is at the most distant location on the volume from the entry port, at least some of the coil wire is in direct contact with the fluid (no insulation between wire and fluid but with electrical insulation between wires), the cavity is generally parallel to a longitudinal axis of the pole, adjacent wires are bonded by adhesive (the wires are glued together to reduce deformation and to retain a fixed bulk geometry), coil wires separate the cavity volume from the inner core, a conductive metal surface separates the cavity volume from the inner core, the conductive metal surface is comprised of a copper foil, and the wires and core are connected by a thermoset polymer, the orientation is of natural convection the fluid undergoes at least partial evaporation in the coil.

[71] Optional enhancement is a heat pipe built into the molded device. This embodiment preferably has: a cooling heat transfer surface (skin) as an outer body surface wherein ducts for flow of the fluid contact the outer heat transfer surface, and the cooling fluid undergoes evaporation between the coil wires and condensation next to the outer surface and wherein at least one duct along the outer heat transfer surfaces connects the entry port to the exit port.

[72] Fig. 7 illustrates the front, horizontal cross section, and side cross section of a toroidal coil with a toroidal cooling cavity in the coil. The figure illustrates an outer core 19, inner core 20, the coil 21, cavity 22 between wires of the coil, a heat transfer fluid entrance 23, and a heat transfer fluid exit 24. Ports on opposite ends of a diameter of the toroid provide locations for a cooling fluid to enter and exit.

[73] The cavity may be end-to-end in the coil. The cavity may be made by rolling a meltable/dissolvable cord next to the wire of a magnetic coil for part of the rolling processing.

[74] Molding of the outer core with or without an outer metal sheet (or foil) layer allows the outer core surface to be ribbed corrugated surface, or otherwise of design for improved heat transfer.

Enhanced Linear Motor Device

[75] Grid power may be distributed in the armature rail of a linear induction motor where the short stator contacts the reactive rail at a point to receive electrical power.

[76] Alternative to an overhead rail where grid power is distributed by the armature rail, the armature rail may be put at ground level with electric power applied to the rail only when a train is the in the proximity. A sensor would sense the train and provide power to the third rail when the rail is near and/or under the train.

[77] The overhead monorail is preferably unrolled from a reel including constructions such as cables (e.g. wire rope), bands (e.g. steel bands), and combinations thereof.

[78] In the production of more-complex motors made possible with molding, an optional embodiment is where the center part of a rotary motor is an open cylinder for air flow and where propellers rotate both in and out of the motor shell surrounding the hollow cylinder center (hollow except for optional propellers). This configuration allows for ram -jet or jet performance options if fuel is burned in the middle part of the engine.

Enhanced Battery-Powered Aircraft and Tethered Gliders

[79] Short-hop battery-powered aircraft potentially have use in major market segments because of high reliability of electric motors and low infrastructure requirements to maintain aircraft without liquid fuel. Enter into this arena electric motors that are 15% to 25% the weight of the current best available technology, and these aircraft can begin to dominate. It is possible to have shorthop aircraft provide costs and access like Megabus, but with transit times faster than any alternative.

Monorail Linear Motor Designed to Handle Sag

[80] A linear motor short stator configured to engage a monorail armature preferably is able to operate with both lift forces on the upper surfaces of the monorail and regular variations of a centimeter or more in the vertical clearance. This operation allows for less expensive rail configurations. This embodiment is comprised of a short stator with lateral clearances between propulsion magnets and the reactive rail of 1 to 10 mm on both sides while vertical clearances may vary from 1 to over 30 mm during transit. Preferably the lower part of the short stator cavity (or other blocking device) is sufficiently distant from the upper surface of the short stator cavity to allow for this variation is vertical location of the monorail in the cavity.

[81] Fig. 8 illustrates a short stator around a monorail without indicating the clearance gaps.

[82] Fig. 8 illustrates aspects of a switching method including a main guideway 25, a switching guideway 26, a narrowed main guideway 27 at the switch location, a main chassis 28, and a switch chassis 29. Fig. 8A) illustrates travel not at a switch location where no switch guideway is present and no derail guard is needed. Fig. 8B) illustrates how aligned main and switch chassis travel right under the switch guideway if a switch is not desired and where the switch rail blocks the main/lower chassis from derailment. Fig 8C) illustrates an approach to a switch location where the switch guideway is switched up in preparation for the switch and a degrail guard bocks the side-rail of the main chassis to prevent derailment where the switch rail can appear gradually from the side as a point (e.g. of an arrow) and gradually broadens along the longitudinal path to substantiate a full guideway width and height. Fig 8D) illustrates the chassis in the switch position at a switching guideway location where vertical separation of the switch rail results in the main/lower chassis slipping up and away from the main guideway.

[83] The most-preferred embodiment of this invention is an aircraft with an upper lift path surface (hereafter upper LiftPath) and a lower lift path surface (hereafter lower LiftPath) on the upper and lower surfaces of the fuselage, respectively. The LiftPaths are generally rectangular in shape having a width similar to the fuselage width and a length along most of the fuselage. During flight the LiftPaths bend air downward to create a lift force and transfer that force to the aircraft on surfaces of relatively low pitch so as to preserve a high ratio of lift to drag forces. Preferred applications include but are not limited to fixed wing aircraft and tethered lifting-body gliders.

[84] Surface slant 30 (also referred to as slant angle) is illustrated by Fig. 9 and is critical in the specifying of the embodiments of this invention. In this Specification and Claims, slant 30 is an angle formed in the vertical -lateral plane between a line tangent 31 to a surface 32 and a horizontal plane 33 with the vertex 34 at the aircrafts plane of symmetry. Surface slant 30 is defined for a surface with the aircraft at zero roll and zero angle of attack. In a forward facing position, positive slant angle changes are counterclockwise for upper surfaces on starboard side and lower surfaces on port side and clockwise for upper surfaces port side and lower surfaces starboard side. [85] The Liftpath width 35 is defined in terms of a generally flat, concave, or piecewise flat surface said width 35 having a horizontal lateral dimension of length between points on LiftPath edges said edges generally specified wither the surface slant progresses from more than -8 degrees to less than -8 degrees.

More Preferred Embodiment

[86] In the more-preferred embodiment, the aircraft has: a center of gravity, an exterior surface, an aircraft front, an aircraft tail, a maximum width, surface pitch angles relative to a reference plane, and surface slant angles 1.

[87] The more-preferred aircraft comprises (a) a fuselage; (b) a plurality of high-lift-to- drag-capturing surfaces having: surface areas, pitch angles between 0 and 2 degrees, an average pitch angle, and slant angles between -4 and 4 degrees; (c) a plurality of lift- stabilizing surfaces located behind the center of gravity having: surface areas, pitch angles between -2 and 1 degrees, slant angles between -4 and 4 degrees, and an average pitch angle less than the average pitch angle of the lift-to-drag capturing surfaces; (d) at least one lift path surface (LiftPath) extending longitudinally on the fuselage having: a median width, a median length, a surface area, a fore end, an aft end, a port edge, and a starboard edge; and (e) a payload compartment in the fuselage having a median maximum width and a median length.

[88] Further more-preferred aspects are the aircraft wherein: (i) the lift path surface is within the aircraft's exterior surface with a transition from the edges and ends of the lift path surface wherein the transition at the port and starboard edges has slants greater than -2 degrees, the transition at the aft end has pitches greater than -2 degrees, and the transition at the fore end has pitches less than 4 degrees, (ii) the lift path surface's median width is greater than one ninth the aircraft's maximum width, (iii) the lift path surface's median width is between than eight tenths and twelve tenths the payload compartment's median maximum width, (iv) the lift path surface's median length is greater than seven tenths the payload compartment's median length, (v) greater than one fourth of the total lift path's surface area is comprised of lift-stabilizing surface areas, (vi) greater than two thirds of the total lift path surface areas are comprised of high-lift-to-drag-capturing surface areas, and (vii) the pitch reference plane is the plane of tangency on the lift path at the lift path's closest point to the aircraft's center of gravity.

[89] Preferably the lift-stabilizing surface area behind the center of gravity is between 53% and 70% of the total high-lift-to-drag-capturing surface area.

[90] Optionally, there are fences on both sides of the lift path surface wherein the fence has a vertical extension between 2% and 20% of the lift path's median width and an outward horizontal extension between 0% and 20% of the lift path's median width. Preferably the lift path's surface connects smoothly and continuously with a wing's surface and the fence's vertical extension goes to zero at a location by the wing's surface.

[91] Optionally, there is a platform on each side of the fuselage, each said platform having a vertical thickness between 1% and 20% of the lift path's median width, a width between 1% and 70% of the lift path's median width, a length between 30% and 100% of the lift path's median length; wherein, the lift path's surface connects smoothly and continuously with a platform surface and the fence's vertical extension goes to zero at a location by the platform's surface..

[92] Optionally, there is a cabin walk-path vertical extension of the lift path surface said extension expanding a portion of the lift path surface away from the payload compartment wherein said expansion has a width between one and four feet.

[93] Optionally, there is an upper lift path surface wherein said upper lift path surface is a lift path surface on the top of the fuselage. Optionally, there is a pressure-reducing canopy having a continuous and smooth surface connection to the fore end of the upper lift path surface wherein: said pressure reducing canopy having a median slant between -4 and 4 degrees, a forward pitch of less than -10 degrees, a continuous mid-section pitch reaching a peak height at a zero degree pitch, a starboard side, a port side, a width extending from the lift path port side to the lift path starboard side, and a smooth surface connection to upper lift path surface. Optionally, there are fences on both sides of the pressure reducing canopy wherein the fences have equal vertical extensions between 2% and 20% of the lift path's median width and an outward horizontal extension between 0% and 20% of the lift path's median width Optionally, there is an upper rear wing said upper rear wing having an upper surface and a lower surface wherein the lift path's surface connects smoothly and

continuously with the upper rear wing's upper surface.

[94] Optionally, there is a lower lift path surface wherein said lower lift path surface is a lift path surface on the bottom of the fuselage. Optionally, there is a pressure-generating surface having a continuous and smooth surface connection to the lower lift path surface wherein: said pressure generating surface having a median pitch between 50 and 20 degrees on the front of the fuselage, a median slant between -4 and 4 degrees, and a continuous decrease in surface pitch until the smooth and continuous connection with the lower lift path surface. Optionally, there are fences on both sides of the pressure-generating surface wherein the fences have equal vertical extensions between 2% and 20% of the lift path's median width and an outward horizontal extension between 0% and 20% of the lift path's median width. Optionally, there is an upper rear wing said lower rear wing having an upper surface and a lower surface wherein the lift path's surface connects smoothly and

continuously with the lower rear wing's lower surface.

[95] Optionally, there is an upper rear wing, a lower rear wing, and fuselage sides, wherein the distance between the fuselage sides decreases to a vertical edge between the upper rear wing and the lower rear wing.

[96] Optionally, there is one or more rear wings where the rear wing is a swept wing. [97] Optionally, there is a wing, an energy storage means, and a propulsion means wherein the wing has a wingspan greater than three times the median maximum payload compartment width.

[98] Optionally, there is a tether wherein the aircraft is a tethered glider and the tether pulls the aircraft along a guide way.

[99] Optionally the aircraft is in supersonic flights and wherein a Liftpath is on the upper surface of the fuselage.

[100] Optionally, there is a rudder at the feed or discharge of a rear propeller wherein the rudder in a state of hovering flight.

[101] Alternatively, the lift path surface embodiment is an embodiment of lift path surface sections, where: (d) a plurality of lift path surface sections extending longitudinally on the fuselage having: a median width, a median length, a cumulative surface area of all lift path sections, fore ends, aft ends, port edges, starboard edges, and a lift path section of closest approach the aircraft's center of gravity. Here the limits on "surface's" of the preferred embodiment apply to the "surface sections 's".

[102] An alternative design is a wide-body configuration. For flight at lower pressures (e.g. 0.2 atm), the fuselage cross section of Fig. 10 has distinct advantages to further increase L:D and have costs comparable to tubular designs. The Fig. 10 design is a wide body with seating in the middle and both sides and two walkways 37. Additions (sharper corners) to build up the sides of the upper and lower platforms are a good option (with fences) and are illustrated in the left option versus the right option. Example seating is 5 across in the middle, and 3 across on both sides. Within the cabin, cables, trusses or other devices 38 may connect the upper surface to the lower surface for structural support. Those supports 38 are preferably intermittent.

Enhanced Molded Induction Welder [103] High temperature electromagnets can be made by using liquid or muds that form solids that can withstand high temperatures, solids such as ceramics and porcelain. Bare, rather than insulated wires can be used if the solid-forming material is non-conducting.

[104] Electromagnetic coils encased in high-temperature housing may be used to weld materials using a system having two electromagnetic functions. A first coil (electromagnetic) holds paramagnetic materials in place using magnetic forces, for example, with a direct current energizing. A second coil performs induction heating to melt the metals of two sheets or a binding metal between sheets. In the absence of moving the coils, it is a spot welder or spot brazer.

[105] The first coil(s) pulls, holds, and secures the paramagnetic materials against the welder surface. Preferably, the coils in the welder are cooled using a passive cooling fluid with a natural convection loop. For brazing, the melting binder may be placed between the metals, optionally in grooves (or space between metals) prior to initiating the welding process. The second coil may be physically inside the first coil.

Claims

1. A method for fabricating an electromagnetic device comprising:

placing at least one insulated wire coil in a mold,

placing a solid-forming liquid in the mold,

placing a plurality of solid particles in the mold said solid particles having saturation fluxes greater than 0.5 Tesla,

applying voltage to said wire coil,

wherein the coil forms a magnetic field said magnetic field changes the solid particle positions forming volumes of increased solid particle concentrations, and

wherein the solid-forming liquid forms a solid.

2. The method of Claim 1 wherein the solid-forming liquid is a monomer mixture and the solid is a polymer.

3. The method of Claim 1 wherein the solid-forming liquid is a mud mixture and the solid is a ceramic.

4. The method of Claim 1 comprising placing a duct-forming insert in the mold.

5. The method of Claim 1 comprising placing a rotating device in the mold said rotating device is coated with a removable coating.

6. The method of Claim 1 comprising placing a magnet outside the mold that is pole-to- pole with an inner core to be formed in the mold.

7. The method of Claim 1 comprising placing a paramagnetic object having at least one dimension greater than 1.0 mm in the position of an inner core of the wire coil.

8. The method of Claim 1 wherein the device is a joint flexible in directions lateral to longitudinal dimension of an inner core pole and where increased current in a coil surrounding the pole increases stiffness of the joint.

9. The method of Claim 8 comprising placing multiple paramagnetic objects in the position of an inner core of the wire coil said paramagnetic objects each having at least one dimension greater than 1.0 mm.

10. A molded electromagnetic device comprised of

an exterior wall and an electromagnet coil,

a continuous polymer phase said polymer phase comprising a thermoset polymer surrounding a plurality of particles having saturation fluxes greater than 0.5 Tesla, wherein the thermoset polymer and particles form a solid composite said composite having a plurality of regions of different average densities and

wherein a first region of highest average density forms an inner core, a second region of lower particle density is adjacent to the coil and outside the coil, and a third region of lowest particle density is outside the coil and further distant from the coil than the second region, and

wherein the second region is at least in part comprised of objects having saturation fluxes between 0.5 and 2.5 with maximum dimensions less than 1 mm surrounded by a continuous solid phase having a saturation flux less than 0.4.

11. The device of Claim 10 wherein the third region of lowest particle density forms the outer wall of the electromagnetic device.

12. The device of Claim 10 wherein said electromagnetic device comprises a first coil, a second coil, and a cooling fluid duct between the first and second coil.

13. The device of Claim 10 where the device is a joint having controlled flexibility comprising

a flexible electromagnet core said core having discrete paramagnetic sections separated by flexible sections along a longitudinal dimension of the core,

a coil surrounding the flexible electromagnetic core,

whereby increased current in the coil induces increased longitudinal attractive forces of the discrete paramagnetic sections resulting in greater resistance to core flexibility in at least one direction perpendicular to the longitudinal axis of the core.

14. The joint of Claim 13 where the flexible sections are thermoset polymer.

15. The joint of Claim 13 where the end-to-end adjacent paramagnetic sections have matching male and female geometries where the male geometry is of a shape between that of a ball and a cone.

16. The device of Claim 10 comprising

a cooling cavity located between coil wires said cavity comprising a volume of fluid, an entry port, and an exit port,

whereby a fluid flows through the entry port, volume, and exit port,

wherein said fluid removes heat from the coil wires.

17. The device of Claim 16 comprising a cooling heat transfer surface (skin) as an outer body surface wherein ducts for flow of the fluid contact the outer heat transfer surface, and the cooling fluid undergoes evaporation between the coil wires and condensation next to the outer surface and wherein at least one duct along the outer heat transfer surfaces connects the entry port to the exit port.

18. An electromagnet device comprising

a tube bent into a coil configuration said tube comprising a first end, a second end, and a fluid volume;

insulation on the outer surface of the coil;

plurality of electromagnetic core regions of different average densities;

a fluid entry port located on the first end and a fluid exit port on the second end;

an electric circuit connection surface near the first end and a circuit-completing connection on the second; and

wherein the tubes are surrounded by a continuous solid phase.