Three-Dimensional-Flux Electric Motor And Method For Making Thereof

A method of making a stator, comprising:

• providing a yoke, wherein the yoke comprises a spray-formed yoke;
• providing a tooth ring, wherein the tooth ring is a spray-formed tooth ring;
• separating portions of the tooth ring to form a plurality of teeth;
• arranging the separated teeth in a circular pattern, wherein each separated tooth is spaced from an adjacent tooth;
• inserting a coil over each separated tooth;
• locating the yoke onto the plurality of teeth;
• placing the yoke into an encapsulation mold;
• connecting the coils to each other;
• and
• injecting a resin into the encapsulation mold.

A method of assembling a stator/rotor assembly for a motor, the method comprising:

• providing a housing having a bearing sleeve, the bearing sleeve extending radially inward in the housing;
• providing a stator, wherein the stator comprises,
• a spray-formed stator yoke,
• a plurality of teeth arranged in a spaced relationship on the stator yoke, and
• a coil inserted over each of the separated teeth and connected to coils inserted over adjacent separated teeth;
• mounting the stator in the housing on the bearing sleeve;
• mounting bearings proximate the bearing sleeve;
• and
• mounting a rotor comprising a rotor yoke and a plurality of magnets on the bearing sleeve, wherein mounting the rotor on the bearing sleeve comprises inserting the rotor into the housing using a gradual and controlled insertion such that an air gap is formed between the stator and the rotor, the air gap being substantially planar and normal to an axis of rotation of the rotor relative to the stator.

A stator for a three-dimensional flux electric motor, the stator comprising:

• a stator yoke;
• a plurality of teeth arranged on the stator yoke, wherein teeth of the plurality of teeth are spaced from each other;
• and
• a coil located over each tooth, the coils over each tooth being connected to coils on adjacent teeth;
• wherein each tooth of the plurality of teeth includes a body portion having three sides connected along respective opposing side edges, each of the three sides having a bottom edge and a top edge adjacent to the opposing side edges, and a top portion located on the top edges;
• wherein the top portion of each tooth includes an overhang portion that overhangs the top edges of the body portion;
• and
• wherein each tooth of the plurality of teeth provides for at least a magnetic flux flow in axial, radial, and circumferential directions.

A three-dimensional flux electric motor, comprising:

• a housing comprising a bearing sleeve extending radially inward in the housing;
• at least one stator mounted on the bearing sleeve in the housing, the at least one stator comprising,
• a spray-formed stator yoke,
• a plurality of teeth arranged on the stator yoke and spaced from each other, and
• a coil over each tooth, the coils over each tooth being connected to coils on adjacent teeth,
• wherein each tooth of the plurality of teeth includes a body portion having three sides, each of the three sides having a bottom edge and a top edge, and a top portion located on the top edges,
• wherein the top portion includes an overhang portion that overhangs the top edges of the body portion, and
• wherein each tooth of the plurality of teeth provides for a magnetic flux flow in axial, radial, and circumferential directions;
• and
• at least one rotor mounted on the bearing sleeve, the at least one rotor comprising,
• a rotor yoke, and
• a plurality of magnets on the rotor yoke;
• wherein the at least one stator and the at least one rotor are separated by an air gap.