# US 12,015,316 B2 · High temperature and high power density axial flux motor > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,015,316 B2 - Document ID: US12015316B2 - Status: Granted - Kind: B2 - Application number: 17/557,798 - Filed: 2021-12-21 - Published: 2023-04-20 - Granted: 2024-06-18 - Earliest claimed: 2021-10-19 - Assignees: Honeywell International Inc. - Applicants: Honeywell International Inc. - Inventors: Chandan Kumar; Deepak Pitambar Mahajan; Renukaprasad N; Subhashree Rajagopal - Web page: https://patentgrep.com/patent/US12015316B2 ## CPC - H02K 3/24: with channels or ducts for cooling medium between the conductors - H02K 1/2798: where both axial sides of the stator face a rotor - H02K 3/22: consisting of hollow conductors - H02K 15/12: Impregnating, moulding insulation, heating or drying of windings, stators, rotors or machines - H02K 21/24: with magnets axially facing the armatures, e.g. hub-type cycle dynamos - H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53}) ## Abstract An axial flux motor may include a motor housing, a shaft rotatably mounted in the housing, and a stator mounted in the motor housing, and having a stator ring and a through-hole through which the shaft extends. Two rotors may be 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 surface thereof. In addition, magnet wire may be wound on portions of 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. ## Claims ### Claim 1 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 stator ring and a through-hole through which the shaft extends; 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 surface thereof; and a magnet wire wound on portions of 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. ### Claim 2 (depends on 1) The motor of claim 1, wherein axial air gaps are provided between the stator and each of the two rotors with respect to a longitudinal axis of the shaft. ### Claim 3 (depends on 1) The motor of claim 1, wherein the magnet wire is wound in a multi-phase winding. ### Claim 4 (depends on 3) The motor of claim 3, wherein the magnet wire is wound in a three-phase winding. ### Claim 5 (depends on 1) The motor of claim 1, wherein the plurality of magnets on each of the rotors includes magnets arranged in a Halbach magnet array. ### Claim 6 (depends on 1) The motor of claim 1, wherein the stator comprises a non-magnetic core formed of a material selected from a group consisting of ceramic, carbon fiber, and/or aluminum. ### Claim 7 (depends on 1) The motor of claim 1, wherein the stator is formed of a grain oriented magnetic steel. ### Claim 8 (depends on 1) The motor of claim 1, wherein the stator is formed of an amorphous metal. ### Claim 9 (depends on 1) The motor of claim 1, wherein each of the two rotors is a disc, and wherein each of the two rotors is formed of a material selected from a group consisting of ceramic, carbon fiber, and/or aluminum. ### Claim 10 (depends on 1) The motor of claim 1, wherein the stator further comprises steel lamination. ### Claim 11 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. ### Claim 12 (depends on 11) The motor of claim 11, wherein axial air gaps are provided between the stator and each of the two rotors with respect to a longitudinal axis of the shaft. ### Claim 13 (depends on 11) The motor of claim 11, wherein the plurality of magnets on each of the rotors includes magnets arranged in a Halbach magnet array. ### Claim 14 (depends on 11) The motor of claim 11, wherein the stator further comprises steel lamination. ### Claim 15 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. ### Claim 16 (depends on 15) The method of claim 15, wherein axial air gaps are provided between the stator and each of the two rotors with respect to a longitudinal axis of the shaft. ### Claim 17 (depends on 15) The method of claim 15, wherein the magnet wire is wound in a multi-phase winding. ### Claim 18 (depends on 17) The method of claim 17, wherein the magnet wire is wound in a three-phase winding. ### Claim 19 (depends on 15) The method of claim 15, wherein the plurality of magnets on each of the rotors includes magnets arranged in a Halbach magnet array. ### Claim 20 (depends on 15) The method of claim 15, wherein the stator further comprises steel lamination.