# US 12,003,150 B2 · Electrical machine having a plastic layer as a phase separator > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,003,150 B2 - Document ID: US12003150B2 - Status: Granted - Kind: B2 - Application number: 17/263,076 - Filed: 2019-07-24 - Published: 2021-10-07 - Granted: 2024-06-04 - Earliest claimed: 2018-08-03 - Assignees: Innomotics GmbH - Applicants: Innomotics GmbH - Inventors: Klaus Büttner; Tobias Katzenberger; Bastian Plochmann; Matthias Warmuth - Web page: https://patentgrep.com/patent/US12003150B2 ## CPC - H02K 15/105: {to the windings} - H02K 3/28: Layout of windings or of connections between windings (windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32) - H02K 3/38: around winding heads, equalising connectors, or connections thereto - H02K 15/12: Impregnating, moulding insulation, heating or drying of windings, stators, rotors or machines - H02K 15/35: Form-wound windings - B05C 5/0216: {by relative movement of article and outlet according to a predetermined path} - B05C 7/02: the liquid or other fluent material being projected - H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53}) - B05C: APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (spraying apparatus, atomising apparatus, nozzles B05B; plant for applying liquids or other fluent materials to objects by electrostatic spraying B05B5/08) ## Abstract A stator of a rotary electrical machine includes a laminated core having grooves, windings inserted into the grooves for forming a multi-phase winding system, and an insulating layer made of plastic and sprayed between partial winding overhangs of the windings of phases inserted immediately one after the other. The insulating layer is formed as a mesh-like structure having junctions and brace-like connections running between the junctions. ## Claims ### Claim 1 A method for producing a stator of a rotary electrical machine, said method comprising: inserting windings of individual phases sequentially into grooves of a laminated core to form a multi-phase windings system; and spraying between insertion of a one of the windings of one of the phases and insertion of a one of the windings of a next one of the phases an insulating layer of plastic at least onto a partial winding overhang of the windings, such that the insulating layer forms a mesh-like structure having junctions and brace-like connections running between the junctions. ### Claim 2 (depends on 1) The method of claim 1, wherein the insulating layer is sprayed onto the partial winding overhang of all the windings that have already been inserted at a time of spraying the insulating layer. ### Claim 3 (depends on 1) The method of claim 1, further comprising spraying a further insulating layer of plastic onto the laminated core before the windings are inserted into the grooves, such that the further insulating layer forms a mesh-like structure having junctions and brace-like connections running between the junctions. ### Claim 4 (depends on 1) The method of claim 1, further comprising spraying a further insulating layer of plastic onto partial winding overhangs of the wings of all phases after insertion of the windings into the grooves, such that the further insulating layer forms a mesh-like structure having junctions and brace-like connections running between the junctions. ### Claim 5 (depends on 1) The method of claim 1, wherein the insulating layer comprises a plurality of superimposed strands of plastic. ### Claim 6 (depends on 1) The method of claim 1, further comprising moving a nozzle head translationally as the insulating layer is sprayed via a rotating outlet nozzle of the nozzle head and the plastic emerges from the rotating outlet nozzle in the form of a strand. ### Claim 7 (depends on 1) The method of claim 1, wherein the plastic is a plastic which cross-links when exposed to moisture and/or on contact with air, or a plastic which does not cross-link when exposed to moisture and/or on contact with air. ### Claim 8 (depends on 1) The method of claim 1, wherein the plastic has a melting temperature or glass transition temperature of at least 120° C. ### Claim 9 (depends on 1) The method of claim 1, wherein the plastic is a thermoplastic hot-melt adhesive or a thermoset. ### Claim 10 (depends on 1) The method of claim 1, wherein the plastic has a melting temperature or glass transition temperature of at least 150° C. ### Claim 11 (depends on 1) The method of claim 1, wherein the plastic has a melting temperature or glass transition temperature of at least 180° C. ### Claim 12 (depends on 1) The method of claim 1, wherein the plastic has a melting temperature or glass transition temperature of at least 200° C. ### Claim 13 (depends on 1) The method of claim 1, wherein the thermoplastic hot-melt adhesive is a polyolefin, or wherein the thermoset cross-links under UV light at room temperature. ### Claim 14 A stator of a rotary electrical machine, said stator comprising: a laminated core having grooves; windings inserted into the grooves for forming a multi-phase winding system; and an insulating layer made of plastic and sprayed between partial winding overhangs of the windings of phases inserted immediately one after the other, said insulating layer formed as a mesh-like structure having junctions and brace-like connections running between the junctions. ### Claim 15 (depends on 14) The stator of claim 14, wherein the insulating layer is arranged between the partial winding overhangs arranged closer to the stator and the partial winding overhangs arranged further from the stator. ### Claim 16 (depends on 14) The stator of claim 14, further comprising a further insulating layer made of plastic and arranged between the laminated core and the partial winding overhangs of the windings, said further insulating layer formed as a mesh-like structure having junctions and brace-like connections running between the junctions. ### Claim 17 (depends on 14) The stator of claim 14, further comprising a further insulating layer made of plastic and arranged on the partial winding overhangs of the windings on a side facing away from the laminated core, said further insulating layer formed as a mesh-like structure having junctions and brace-like connections running between the junctions. ### Claim 18 (depends on 14) The stator of claim 14, wherein the insulating layer comprises a plurality of superimposed strands of the plastic. ### Claim 19 (depends on 14) The stator of claim 14, wherein the insulating layer comprises a plurality of coherent rings having a diameter, said coherent rings arranged offset from one another by an offset sized smaller than the diameter. ### Claim 20 (depends on 14) The stator of claim 14, wherein the plastic is a plastic which cross-links when exposed to moisture and/or on contact with air. ### Claim 21 (depends on 14) The stator of claim 14, wherein the plastic is a plastic which does not cross-link when exposed to moisture and/or on contact with air. ### Claim 22 (depends on 14) The stator of claim 14, wherein the plastic has a melting temperature or glass transition temperature of the plastic is at least 120° C. ### Claim 23 (depends on 14) The stator of claim 14, wherein the plastic is a thermoplastic hot-melt adhesive or a thermoset. ### Claim 24 (depends on 14) The method of claim 14, wherein the thermoplastic hot-melt adhesive is a polyolefin, or wherein the thermoset cross-links under UV light at room temperature. ### Claim 25 A rotary electrical machine, comprising: a rotor; and a stator interacting with the rotor and comprising a laminated core having grooves, windings inserted into the grooves for forming a multi-phase winding system, and an insulating layer made of plastic and sprayed between partial winding overhangs of the windings of phases inserted immediately one after the other, said insulating layer formed as a mesh-like structure having junctions and brace-like connections running between the junctions.