EP0644645A2
Expired / Lapsed
EP
⏱️ 0.0 years remaining
Slotless electric motor or transducer and method for making same
Assignee: Advanced Interconnection Technology Inc
•
Filing: 1994-09-05
•
Granted: —
•
Expires: 2014-09-05
Abstract
Abstract A slotless stator for an electromechanical transducer, said stator including a stator shell (30) and a pre-formed, at least partially rigid, self-supporting winding structure having active segments and end-turns (40), is produced by a method that comprises depositing insulated wire on a support, adhesively affixing at least active wire segments portions to the support surface or previously deposited wires, with the active wire segments arranged in predetermined, substantially fixed positions with respect to each other, encapsulating and securely attaching the winding structure to the stator shell, and combining the completed stator with a structure including at least one permanent magnet mounted for movement relative to the stator. In a preferred embodiment, the self-supporting winding structure is removed from the support surface prior to insertion in the stator shell. <IMAGE>
Inventors
- 👤 Richard J. Fougere
- 👤 Mohammad Khandan-Barani
- 👤 Raymond S. Keogh
Bibliographic Details
Application Number
—
Jurisdiction
EP
Data Source
google_patents
Last Synchronized
2026-11-02 23:47
CPC Classifications
H; H02; H02K; H02K15/00; H02K15/04; H02K15/043; H02K15/0431; H02K15/02; H02K3/00; H02K3/46; H02K3/47; H02K15/12; H02K21/00; H02K21/12; H02K21/14; H02K41/00; H02K41/02; Y; Y10; Y10T; Y10T156/00; Y10T156/17; Y10T156/1702; Y10T156/1712; Y10T156/1737; Y10T29/00; Y10T29/49; Y10T29/49002; Y10T29/49009; Y10T29/49012; Y10T29/4902; Y10T29/49073; Y10T29/51; Y10T29/5136; Y10T29/5137; Y10T29/53; Y10T29/5313; Y10T29/53143; Y10T29/53161
Claims Analysis
Total Claims: 48
Claim 1
Independent Claim
122 words
A method for the manufacture of a slotless stator for an electromechanical transducer including a pre-formed, at least partially rigid, self-supporting winding structure having active segments and end-turn segments, said method comprising the steps of depositing insulated wire on a support surface; adhesively affixing at least active wire segment portions of said insulated wire to said support surface or previously deposited wires, 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; encapsulating and securely attaching said winding structure to the metal structure of the slotless stator; and combining the completed stator with one or more permanent magnet structures mounted for movement relative to said stator.
Claim 2
Dependent Claim
24 words
The method of claim 1 wherein the winding structure is removed from said support surface and inserted in the slotless stator structure or shell.
Claim 3
Dependent Claim
18 words
The method of claim 1 or 2 wherein said active segments are arranged substantially parallel to each other.
Claim 4
Dependent Claim
40 words
The method of claim 1 wherein the support surface, or the wire, or both, is (are) provided with an adhesive layer that is activated substantially simultaneously with, or subsequent to, the application of each conductor segment of the winding structure.
Claim 5
Dependent Claim
29 words
The method of claim 1 or 2 wherein the electromechanical transducer is a rotary motor and wherein said active segments are arranged substantially parallel to the axis of rotation.
Claim 6
Dependent Claim
29 words
The method of claim 1 or 2 wherein the electromechanical transducer is a linear motor and wherein said active segments are arranged substantially perpendicular to the direction of movement.
Claim 7
Dependent Claim
24 words
The method of claim 1 wherein at least part of the active segments is adhesively fixed in position prior to depositing subsequent active segments.
Claim 8
Dependent Claim
49 words
The method of claim 1 wherein at least one or more section(s) of active wire segment portions of said insulated wire is (are) adhesively affixed to said support surface or previously deposited wires, with at least one active wire segment, or part of such segment, attached at a time.
Claim 9
Dependent Claim
35 words
The method of claim 8 wherein the adhesive coated wire is activated while depositing said wire by progressively applying sufficient energy at the point of contact for adhering the wire to form said winding structure.
Claim 10
Dependent Claim
19 words
The method of claim 8 wherein the adhesive coated wire is activated for an entire segment at one time.
Claim 11
Dependent Claim
17 words
The method of claim 8 wherein the adhesive coated wire is activated intermittently for an active segment.
Claim 12
Dependent Claim
28 words
The method of claim 4 wherein the adhesive layer is activated substantially simultaneously with, or subsequently to, the application of each active conductor segment of the winding structure.
Claim 13
Dependent Claim
25 words
An electromechanical transducer comprising the stator of claim 1 or 2 and one or more permanent magnet structure(s) mounted for movement relative to said stator.
Claim 14
Dependent Claim
20 words
An electric motor comprising the stator of claim 1 or 2 and a rotor comprising one or more permanent magnet(s).
Claim 15
Dependent Claim
23 words
An electric motor comprising the stator of claim 1 or 2 and one or more permanent magnet(s) movable linearly relative to said stator.
Claim 16
Independent Claim
273 words
A method for the manufacture of a rotating electromechanical transducer including a slotless stator with a pre-formed, at least partially rigid winding structure inside a stator shell and a rotor provided with one or more permanent magnet(s), said method comprising the steps of (1) placing 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 surface while travelling towards one end of said support surface 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 travelling 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, a section at a time, 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 electromechanical transducer to include at least one rotating permanent magnet rotor structure.
Claim 17
Independent Claim
283 words
A method for the manufacture of a rotating electromechanical transducer including a slotless stator having a metal structure with a pre-formed, at least partially rigid winding structure inside a stator shell and a rotor provided with one or more permanent magnet(s), said method comprising the steps of (1) dispensing and depositing insulated wire with wire scribing means on a cylindrical support surface, either said insulated wire or said cylindrical surface, or both, being 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 surface while travelling towards one end of said support surface 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 travelling 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) substantially simultaneously with dispensing at least part of said insulated wire, adhesively attaching at least portions of each active conductor segment on a continuous basis to form a cylindrical winding structure with at least the active conductor portions being adhered; (3) encapsulating said winding structure with a resinous composition while simultaneously adhesively bonding said winding structure of the stator shell; (4) disposing a rotor with at least one permanent magnet within said winding structure and completing the assembly of the electromechanical transducer.
Claim 18
Dependent Claim
34 words
The method of claim 1, 16 or 17, further including the step of compressing said winding structure by exerting pressure, or pressure and heat, sufficient to temporarily convert the adhesive to a plastic state.
Claim 19
Dependent Claim
25 words
The method of claim 18 wherein said winding structure is compressed before encapsulating and securely attaching it to the metal structure of the slotless stator.
Claim 20
Dependent Claim
18 words
The method of claim 18 wherein the step of compressing is carried out with the step of encapsulating.
Claim 21
Dependent Claim
32 words
The method of claim 16 or 17 wherein said end-turns, at least at one end of said winding structure, are displaced in a direction perpendicular to the axis of the cylindrical support.
Claim 22
Dependent Claim
22 words
The method of claim 21 wherein said winding structure is inserted in a slotless stator shell with the inwardly displaced end-turns first.
Claim 23
Dependent Claim
38 words
The method of claim 16 or 17 further outwardly compressing the winding structure by inserting an expandable means therein and exerting outwardly directed pressure, or pressure and heat, for temporarily converting the adhesive to its activated plastic state.
Claim 24
Dependent Claim
79 words
The method of claim 1 or 16 wherein the insulated wire is adhesive coated and located between guides relative to said cylindrical support surface to form active conductor segments extending substantially parallel to the axis of said cylindrical support, further comprising applying tension to the insulated wire between said guides, and affixing at least a portion of the active segments to the said support surface, or the surface of a previously formed conductor layer, after tension has been applied.
Claim 25
Dependent Claim
20 words
The method of claim 1, 16 or 17 wherein the winding structure is arranged in a plurality of conductor layers.
Claim 26
Dependent Claim
22 words
The method of claim 1 or 25 wherein adhesive is applied to a deposited wire prior to depositing the next winding layer.
Claim 27
Dependent Claim
23 words
The method of claim 1, 16 or 17 wherein the adhesive is activated by the application of ultrasonic, infrared, heat or laser energy.
Claim 28
Dependent Claim
50 words
The method of claim 1, 16 or 17 wherein the adhesive, in its non-activated state, is solid and non-tacky, can be activated to its active, tacky and plastic state by application of energy of a certain level, and reverts to its solid, non-tacky state when energy is no longer applied.
Claim 29
Dependent Claim
43 words
The method of claim 28 wherein the adhesive may be activated to its tacky state by application of energy at one level and, in a later step, may be fully cured to its thermoset state by application of energy at a higher level.
Claim 30
Dependent Claim
24 words
The method of claim 1, 16 or 17 wherein the encapsulant for encapsulating the winding structure, and the adhesive are substantially completely cured simultaneously.
Claim 31
Dependent Claim
35 words
The method of claim 1, 16 or 17 wherein the end-turns are reformed by application of pressure or heat, or both, bring said end-turn closer to, or in mechanical contact with, the stator shell surface.
Claim 32
Dependent Claim
18 words
The method of claim 1, 16 or 17 wherein the encapsulant comprises a filler with high thermal conductivity.
Claim 33
Dependent Claim
21 words
The method of claim 32 wherein part or all of the filler consists of finely divided particles of magnetically soft material.
Claim 34
Dependent Claim
12 words
The method of claim 33 wherein the magnetically soft material is Met-glass(R).
Claim 35
Dependent Claim
15 words
The method of claim 33 wherein the particles are pre-coated with an electrically insulating layer.
Claim 36
Dependent Claim
45 words
The method of claim 1, 16 or 17 wherein part or all of the magnetic stator structure is formed and attached to the outer surface of said winding structure by injection molding using a resin composition filled with finely divided particles of magnetically soft material.
Claim 37
Dependent Claim
85 words
The method of claim 1, 16 or 17 wherein soft magnetic material wire is applied to the outer surface of the formed winding structure to form the magnetic stator structure surrounding the winding, the method comprising the steps of (a) arranging adhesive coated wire of soft magnetic material in a plurality of layers surrounding said winding structure; (b) adhesively bonding said magnetic material wire to said outer surface of said winding structure and each other; (c) consolidating the resulting structure by applying energy and pressure.
Claim 38
Dependent Claim
13 words
The winding structure made by the method of claims 1, 16 or 17.
Claim 39
Dependent Claim
13 words
The slotless stator made by the method of claims 1, 16 or 17.
Claim 40
Dependent Claim
13 words
The electromechanical transducer made by the method of claims 1, 16 or 17.
Claim 41
Dependent Claim
147 words
Apparatus for manufacturing self-supporting winding structures for slotless stators including a magnetic stator shell comprising a cylindrical carrier mandrel providing a cylindrical support surface; a drive for controlling the rotary position of said mandrel; means for dispensing insulated wire with an adhesive coating that can be activated to a plastic adhesive state by the application of energy; a drive for moving said dispensing means to arrange insulated wire parallel to the axis of said cylindrical mandrel to form active conductor segments of the winding structure and to dispense wire to form end-turns between said active conductor segments; means for activating said adhesive coating to said plastic adhesive state to adhere at least part of said active conductor segments, a section at a time, to form a self-supporting winding structure; and means for inserting said self-supporting winding structure into said stator shell and securing said winding structure therein.
Claim 42
Dependent Claim
23 words
Apparatus according to claim 41 further comprising guide pins in the area of said mandrel to define the end-points for active conductor segments.
Claim 43
Dependent Claim
11 words
Apparatus according to claim 42 wherein said guide pins are retractable.
Claim 44
Dependent Claim
132 words
Apparatus for manufacturing self-supporting winding structures for slotless stators including a magnetic stator shell comprising a cylindrical carrier mandrel providing a cylindrical support surface; a drive for controlling the rotary position of said mandrel; means for dispensing insulated wire with an adhesive coating that can be activated to a plastic adhesive state by the application of energy; a drive for moving said dispensing means to deposit insulated wire parallel to the axis of said cylindrical mandrel to form active conductor segments of the winding structure and to dispense wire to form end-turns between said active conductor segments; means for activating said adhesive coating to said plastic adhesive state on a continuous basis as wire is dispensed to adhere at least part of said active conductor segments to form a self-supporting winding structure.
Claim 45
Dependent Claim
28 words
Apparatus according to claim 42 or 44 wherein said mandrel has reduced diameter areas corresponding to the end-turn portions of the winding structure formed on said support surface.
Claim 46
Dependent Claim
24 words
Apparatus according to claim 42 or 44 including means for dispensing insulated wire capable of dispensing a plurality of wires at the same time.
Claim 47
Dependent Claim
24 words
Apparatus according to claim 42 or 44 including a plurality of means for simultaneously dispensing insulated at different radial positions on said cylindrical support.
Claim 48
Dependent Claim
38 words
An encapsulant for encapsulating and securely attaching a stator winding structure in a stator shell comprising a resin composition wherein at least part of the filler present in said composition consists of powdered particles of magnetically soft material.
References Cited (Backward Citations)
No citation records indexed.
USPTO Annuity & Maintenance Windows
Maintenance schedule is calculated for granted US utility patents.