Twin bobbin C-frame motors and methods for making same

A shaded pole motor comprising:

• magnetically conductive stacked laminations each having an end leg and a generally transversely extending spaced pair of side legs, the spaced pair of side legs each being attached at a first end of said side legs to a marginal end area of said end leg and terminating in an outer free extremity at a second end of said side legs, the combined stacked end legs and spaced pair of stacked side legs providing a first stack of laminations;
• a rotor opening provided in the end leg of each lamination that is aligned with the rotor openings of adjacent stacked end legs to provide an aligned rotor opening in the stacked end legs for receiving a rotor;
• two opposite poles around the aligned rotor opening each having an associated pole shading element;
• each of the spaced pair of stacked side legs at its first end extending from one aligned circumferentially spaced area adjacent to and surrounding the aligned rotor openings, the first end of one of said pair of stacked side legs having a different polarity than the first end of said other stacked side leg, the second end of each stacked side leg having different polarity than at its first end;
• each of the stacked side legs having a combined predetermined length and outer cross sectional configuration coil winding area;
• an electrically conductive coil positioned about the coil winding area of each of the stacked side legs, said electrically conductive coils being connected in series with one another;
• each electrically conductive coil having one coil end positioned in proximity to the aligned circumferentially spaced areas associated with said stacked side legs as well as being adjacent said aligned rotor opening and rotor;
• a corresponding number of separate magnetically conductive stacked laminations providing a second stack of laminations for attachment to the outer free extremity of said spaced pair of stacked side legs in said first stack of laminations in order to provide a combined magnetic inductor circuit therethrough:
• and
• each electrically conductive coil being formed by an electrically conductive wire having a predetermined winding length, predetermined mean winding diameter, and predetermined wire diameter to achieve desired operating efficiency and cost.

A C-frame motor comprising:

• C-frame shaped magnetic inductor circuit means having a pair of spaced side legs extending generally transversely to and being interconnected to outer marginal areas of an end leg at a first end and terminating in a second free end:
• a rotor opening provided in the end leg for receiving a rotor:
• opposite poles around the rotor opening each having an associated pole shading element;
• the pair of spaced side legs at a first end extending from circumferentially spaced areas to the end leg surrounding the rotor opening, the first end of each spaced side leg at said circumferentially spaced areas having an opposite polarity from each other, the polarity at the second free end of the spaced side legs being opposite from the first end;
• each of said spaced side legs having a coil winding area with a combined predetermined length and outer cross sectional configuration, the distance between the spaced side legs providing a joint winding window to accommodate electrically conductive coils on each coil winding area of predetermined length and width:
• an electrically conductive coil positioned about the coil winding area of each of said spaced side legs with one coil end positioned in immediate proximity to one of the circumferentially spaced areas while being adjacent the rotor opening and rotor, said electrically conductive coils being connected in series with one another:
• and
• said magnetic inductor circuit means having a separate end leg for attachment to the free second end of each spaced side leg to complete the magnetic inductor circuit means for the C-frame motor.

A C-frame motor comprising:

• magnetically conductive stacked laminations each having three separate legs including an end leg and two spaced side legs, each of the two spaced side legs extending generally transversely to as well as being connected to outer marginal areas of the end leg while terminating in a free extremity at a second end, the combined stacked configuration of the two side legs and end leg of the stacked laminations providing a series of C-frame shaped stacked laminations;
• a rotor opening provided in each lamination end leg that is aligned with the rotor openings of adjacent C-frame stacked laminations to provide an aligned rotor opening in the end legs of the stacked laminations for receiving a rotor;
• opposite poles around the aligned rotor opening each associated with a pole shading element;
• the spaced two side legs extending from circumferentially spaced areas surrounding the rotor opening in the end leg each having a different polarity at their respective first ends, the second end of each side leg having a different polarity than at its first end;
• each of the side legs having a coil winding area of combined predetermined outer cross sectional configuration;
• an insulating bobbin with wound electrically conductive coil positioned about the coil winding area of the side legs;
• a spaced pair of insulating bobbins positioned about said side legs and being integrally connected to one another while the associated wound electrically conductive coils of said insulating bobbins comprising an electrically conductive wire that is integrally and electrically connected in series and wound about both of said insulating bobbins;
• each electrically conductive coil having one coil end positioned in immediate proximity to one of the circumferentially spaced areas surrounding the rotor opening while also being adjacent the rotor opening and rotor;
• and
• separate magnetically conductive stacked laminations corresponding in number to the C-frame stacked laminations and configured to extend across the side legs for attachment to the second end of the side legs in order to complete a magnetic inductor circuit for the C-frame motor.

An insulating bobbin assembly comprising:

• a spaced pair of insulating bobbins having aligned longitudinal axes which are integrally connected to one another across a living foldable hinge;
• said spaced pair of insulating bobbins being maintained in longitudinal axially aligned relationship during the winding of an electrically conductive wire forming an electrically conductive coil about each bobbin:
• and
• said spaced pair of insulating bobbins being folded about the foldable hinge to position said longitudinal axes of said bobbins in generally parallel relationship for mounting over spaced legs in a magnetic inductor circuit.

A motor comprising:

• magnetically conductive stacked laminations each having a multi-pole portion with a rotor opening and spaced and adjacent side legs extending generally transversely from circumferentially spaced areas of and within the confines of said multi-pole portion, each spaced side leg at its circumferentially spaced area of said multi-pole portion having a different polarity than an adjacent side leg at its circumferentially spaced area of said multi-pole portion, each spaced side leg terminating in an outer free extremity that has a different polarity than at its circumferentially spaced area of said multi-pole portion, the combined stacked laminations providing stacked and spaced side legs in circumferentially spaced areas of stacked multi-pole portions with aligned rotor openings for receiving a rotor;
• each of the stacked and spaced side legs having a combined predetermined length and outer cross sectional coil winding area, the distance between the stacked and spaced side legs providing a joint winding window to accommodate electrically conductive coils on each winding area of predetermined length and width;
• an electrically conductive coil positioned about the coil winding area of each of the stacked and spaced side legs and being connected in series with each other, each electrically conductive coil having one coil end in immediate proximity to its associated circumferentially spaced area of said multi-pole portion while being adjacent the aligned rotor openings and rotor, separate magnetically conductive stacked laminations forming an end leg for attachment to the outer free extremities of spaced and adjacent stacked side legs, and the series connected electrically conductive coils generating flux in one continuous path through the end leg, each side leg, multi-pole portion and rotor of the motor.

A method of forming C-frame laminations each having an end leg integral with spaced side legs from an elongated strip of magnetically conductive material, comprising:

• stamping from said elongated strip adjacent C-frame laminations with the integral end leg and spaced side legs of each lamination in generally opposed mirror image relationship to one another;
• forming a combined predetermined outer cross sectional configuration coil winding area in the spaced side legs of each C-frame laminations:
• and
• forming two separate end legs for attachment to outer free extremities of each pair of spaced side legs, at least one of said separate end legs being formed from said elongated strip.

A method of forming and stacking laminations for C-frame motors, comprising:

• forming a series of magnetically conductive C-shaped laminations each having an end leg with a rotor opening and a spaced pair of side legs integral with and extending from the end leg and terminating in an outer free extremity;
• forming a predetermined outer cross sectional configuration coil winding segment in each of the side legs of said C-frame laminations:
• stacking the C-shaped laminations with the stacked coil winding segments in each of said stacked side legs forming a coil winding area of combined predetermined outer cross sectional configuration;
• forming a series of separate magnetically conductive end leg laminations;
• and
• stacking a series of end leg laminations corresponding in number to said C-shaped laminations for subsequent attachment to the outer free end of said side legs of said C-shaped laminations.

A method of forming a C-frame motor, comprising:

• forming a series of magnetically conductive C-shaped laminations each having an end leg with a rotor opening and a spaced pair of side legs integral with and extending from the end leg with predetermined incrementally varying widths in each of said side legs, each of said side legs terminating an outer free extremity;
• stacking the C-frame laminations in generally vertically aligned relationship in a predetermined sequence with the predetermined incrementally varying widths in each of said side legs forming a coil winding area of generally circular outer cross sectional shape at last along opposed spaced sections;
• forming a series of separate magnetically conductive end leg laminations corresponding in number to said C-shaped laminations for attachment to the outer free extremities of the side legs of said C-shaped laminations;
• stacking said separate magnetically conductive end leg laminations in generally vertically aligned relationship;
• positioning an electrically conductive coil about the coil winding areas of each of said side legs;
• and
• attaching said separate magnetically conductive end leg laminations to the outer free extremities of the side legs of said C-shaped laminations.

The method of forming a motor comprising:

• forming a series of magnetically conductive U-shaped laminations each having an end leg and spaced side legs which terminate in outer free extremities:
• stacking said U-shaped laminations to provide stacked end legs and stacked spaced side legs;
• forming a separate series of magnetically conductive end leg laminations:
• stacking said separate series of magnetically conductive end leg laminations:
• forming aligned rotor openings in one of said end leg laminations for receiving a rotor;
• positioning at least one electrically conductive coil about at least one of the stacked side legs of said stacked U-shaped laminations:
• attaching the separate end leg laminations to corresponding outer free extremities of said spaced side legs of said U-shaped laminations.