Method of making a slotless electric motor or transducer
OwnerRichard J. Fougere, Mohammad Khandan-Barani +1inventors
InventorsRichard J. Fougere, Mohammad Khandan-Barani, Raymond S. Keogh
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Abstract
A method of making a slotless electric motor wherein the active winding segments are adhesively affixed to a support surface or previously deposited active wire segments to form a self-supporting winding structure. The self-supporting structure is then secured in a magnetic structure of the slotless stator.
Claims34
A method for the manufacture of a slotless stator for an electro-mechanical transducer including a magnetic structure and a performed, a least partially rigid, self-supporting, winding structure having an active portion comprising active wire segments and end-turn portions having end turn wire segments, said method comprising the steps of:
- depositing insulated wire on a support surface;
- adhesively affixing at least some of the active segments of said insulated wire to said support surface or previously deposited active wire segments, prior to depositing subsequent active wire segments as said winding structure is formed with at least active wire segments of said winding structure attached in predetermined, substantially fixed positions with respect to other active segments of said winding structure to form a self-supporting winding structure;
- securely attaching said self-supporting winding structure to said magnetic structure of the slotless stator after said winding structure is formed;
- and
- combining the completed stator with one or more permanent magnets mounted for movement relative to said stator.
A method for the manufacture of a rotating electro-mechanical transducer including a slotless stator with a preformed at least partially rigid winding structure inside a stator shell and a rotor provided with one or more permanent magnets, said method comprising the steps of;
- (1) depositing insulated wire on a cylindrical support surface, either said wire or said surface, or both being coated or provided with an adhesive layer that can be activated by application of energy;
- (a) part of said insulated wire being dispensed parallel to the axis of said cylindrical support while traveling toward one end of said support to form an active conductor segment of said winding structure;
- (b) part of said insulated wire being dispensed to form a wire loop constituting an end-turn;
- (c) part of said insulated wire being thereafter dispensed while traveling in the reverse direction parallel to said axis to form another active conductor segment of said winding structure;
- (d) part of said insulated wire being next dispensed to form another wire loop constituting an end-turn;
- (e) repeating steps (a) to (d) until all winding coils of said winding structure are completed;
- (2) adhesively attaching at least portions of each active conductor segment before forming the next segment constituting an active part of a winding structure;
- thereby forming a cylindrical winding structure with at least the active conductor portions being adhered;
- (3) encapsulating said winding structure and simultaneously adhesively bonding it to the stator shell, using as the encapsulant a resinous composition;
- (4) completing the assembly of the electro-mechanical transducer to include at least one rotating permanent magnet within said winding structure.
Dependencies are inferred from the claim text.