High temperature and high power density axial flux motor

An axial flux motor comprising:

• a motor housing;
• a shaft rotatably mounted in the motor housing;
• a stator mounted in the motor housing, and having a through-hole through which the shaft extends, and being formed of a grain-oriented magnetic steel;
• two rotors mounted on the shaft within the motor housing on opposing sides of the stator, each rotor having a plurality of magnets arranged radially on a stator-facing thereof, the two rotors being formed of steel;
• and
• magnet wire wound around the stator, the magnet wire comprising an inner coolant passage disposed within a copper tube, and a green glass coating on an outer surface of the copper tube, the green glass coating comprising glass solids, one or more of surfactants, solvents, and polymers, and the magnet wire being arranged in a three-phase winding.

A method of manufacturing an axial flux motor, the method comprising:

• preparing a magnet wire with a high temperature insulation, including:
• providing a copper tube having a coolant passage therein;
• forming a liquid green glass coating, including suspending glass solids in an aqueous solution containing one or more surfactants, solvents, and polymers;
• coating the copper tube with the liquid green glass;
• and
• heating the coated copper tube, thereby removing carbon from the coated copper wire, and forming the magnet wire;
• forming stator coils by winding the magnet wire around each of a plurality of stator poles;
• dipping the plurality of stator poles including the stator coils into cement;
• baking the dipped plurality of stator poles including the stator coils at a predetermined temperature;
• assembling the plurality of stator poles with a stator ring, thereby forming a stator;
• mounting the stator in a housing;
• mounting a shaft rotatably within the housing, the shaft extending through a through-hole of the stator;
• and
• mounting two rotors on the shaft within the housing, the two rotors being mounted on opposing sides of the stator, and each rotor having a plurality of magnets arranged radially on a stator-facing surface thereof.