Apparatus and method for coating an electromagnetic coil

A method for coating the stator coil of a wound stator core of an electric motor with an insulating catalyzed resin material, wherein the viscosity and the curing rate of the catalyzed resin material is effected by heat and wherein the wound stator core has an axis and includes an iron stator core with slots therein for containing the stator coils and wherein the stator coils protrude axially from both ends of the slots of the iron stator core to form coil heads with interstitial windows between the coil heads, the method comprising the steps of:

• a. Orienting the wound stator core with its axis at a first angle with respect to vertical;
• b. Aligning the nozzle with the coil heads protruding from the stator core:
• c. Rotating the wound stator core about its axis;
• d. Heating the stator coil to a first temperature at which temperature the catalyzed resin material is a free flowing liquid;
• e. Dispensing the catalyzed resin material as a free flowing liquid onto the coil heads by means of a nozzle;
• f. Moving the stator coil and the nozzle relative to each other to insure the catalyzed resin material is uniformly applied to the stator coil including moving the nozzle radially relative to the axis of the wound stator core during dispensing of the catalyzed resin material;
• g. Waiting for the catalyzed resin material to penetrate the stator coil within the slots of the stator core;
• and
• h. Raising the temperature of the stator coil to a second temperature in order to cure the catalyzed resin material in the stator coil.

A method for coating an electromagnetic coil with an insulating catalyzed resin material wherein the viscosity and the curing rate of the catalyzed resin material are affected by heat, the method comprising the steps of:

• a. Heating the coil to a first temperature at which temperature the catalyzed resin material is a free flowing liquid;
• b. Preheating the catalyzed resin material to approximately the first temperature before applying the catalyzed resin material to the coil;
• c. Applying the catalyzed resin material as a free flowing liquid to the coil;
• d. Waiting for the catalyzed resin material to penetrate the coil;
• and
• e. Raising the temperature of the coil to a second temperature in order to cure the catalyzed resin material in the coil;
• wherein the first temperature is selected so that the catalyzed resin material has a viscosity of less than 1000 centipoises.

A method for coating an electromagnetic coil with an insulating catalyzed resin material wherein the viscosity and the curing rate of the catalyzed resin material are affected by heat, the method comprising the steps of:

• a. Heating the coil to a first temperature at which temperature the catalyzed resin material is a free flowing liquid;
• b. Calculating a volume of voids in the coil;
• c. Dispensing that volume of catalyzed resin material onto the coil;
• d. Applying the catalyzed resin material as a free flowing liquid to the coil;
• e. Waiting for the catalyzed resin material to penetrate the coil;
• and
• f. Raising the temperature of the coil to a second temperature in order to cure the catalyzed resin material in the coil.

A method for coating the stator coil of a wound stator core of an electric motor with an insulating catalyzed resin material, wherein the viscosity and the curing rate of the catalyzed resin material is effected by heat and wherein the wound stator core has an axis and includes an iron stator core with slots therein for containing the stator coils and wherein the stator coils protrude axially from both ends of the slots of the iron stator core to form coil heads with interstitial windows between the coil heads, the method comprising the steps of:

• a. Orienting the wound stator core with its axis at a first angle with respect to vertical;
• c. Rotating the wound stator core about its axis;
• d. Heating the stator coil to a first temperature at which temperature the catalyzed resin material is a free flowing liquid;
• c. Aligning a number of nozzles with the coil heads protruding from the stator core;
• d. Dispensing the catalyzed resin material via the nozzles onto the coil heads while the wound stator core rotates about its axis;
• e. Tilting the axis of the wound stator core to a second angle with respect to vertical;
• f. Aligning the nozzles with the coil heads protruding from the stator core;
• g. Dispensing the catalyzed resin material via the nozzles onto the coil heads while the wound stator core rotates about its axis;
• h. Flipping the axis of the wound stator core approximately 180 degrees;
• i. Aligning the nozzles with the coil heads protruding from the stator core;
• j. Dispensing the catalyzed resin material via the nozzles onto the coil heads while the wound stator core rotates about its axis;
• g. Waiting for the catalyzed resin material to penetrate the stator coil within the slots of the stator core;
• and
• h. Raising the temperature of the stator coil to a second temperature in order to cure the catalyzed resin material in the stator coil.