Over molded stator
AssigneeDelaware Capital Formation, Inc.
InventorsStephen Purvines, Gary Glass
Life of this patent
Estimating the term…
Abstract
Devices and methods are provided for an improved motor stator. One embodiment for a stator includes a stator section having a first surface and a second surface each surface having a groove extending into the stator section and a slot extending longitudinally between the first and second surfaces. Insulated conductive wires are wound longitudinally around the stator section in the slots to form winding turns contained completely within each groove. A lead frame extends circumferentially along a surface of the stator and the insulated conductive wires couple to the lead frame. A thermoset material is supplied to the stator section to encapsulate the stator section including the lead frame and the insulated conductive wires, and to provide integral coolant flow passages.
Claims32
A stator, comprising:
- a stator section having a first surface and a second surface each surface having a groove extending into the stator section and slots extending longitudinally between the first and second surfaces;
- insulated conductive wires wound longitudinally around the stator section in the slots to form winding turns contained within each groove;
- a lead frame extending circumferentially along a surface of the stator, wherein the insulated conductive wires couple to the lead frame;
- and
- a thermoset material encapsulating the stator section including the lead frame and the insulated conductive wires.
A stator, comprising:
- a stator housing including:
- first and second axially facing housing members having an inner surface;
- a number of inwardly facing protrusions arranged axially along the inner surface and extending longitudinally between first and second axially facing ends of the first and second housing members;
- and
- a number of coupling members arranged axially along the first and second axially facing ends of the first and second housing members;
- and
- a number of annularly arranged stator sections having at least one recess on an outer surface of each stator section to register with the inwardly facing protrusions.
A stator section, comprising:
- a first end and a second end;
- insulated conductive wires wound longitudinally around the first and second ends to form a stator coil having stacked winding turns extending radially from the first and second ends;
- a number of terminal portions extending from each stator coil a predetermined distance from the winding turns;
- a lead frame electrically coupled to the terminal portions;
- a number of electrical connectors coupled to the lead frame;
- and
- a thermoset material over molded to the stator section such that the thermoset material completely encapsulates the stator section, the insulated conductive wires, the terminal portions, and the lead frame.
An electric motor, comprising:
- a housing having an interior space;
- a rotor rotatably coupled within the interior space of the housing;
- a stator fixedly arranged within the interior space of the housing, the stator including:
- a stator housing;
- a number of annularly arranged stator sections fixed within the stator housing;
- insulated conductive wires wound longitudinally around each stator section, each insulated conductive wire having at least two terminal portions;
- a lead frame for electrically coupling each terminal portion, wherein the lead frame is coupled to an electrical connector;
- and
- a thermoset material completely encapsulating each annularly arranged stator section, the insulated conductive wires, the terminal portions, and the lead frame.
A method, comprising:
- providing a molding tool having a circumferential wall and a end cap, wherein the circumferential wall includes an inner surface with an inwardly facing protrusion, and wherein the end cap includes a path extension;
- registering a stator section having a recess on an outer surface of the stator section with the inwardly facing protrusion;
- and
- supplying the molding tool with a thermoset material to completely encapsulate the stator section except an electrical connector coupled to the stator section.
Dependencies are inferred from the claim text.