Method of making a motor stator

Claim 1

The method of forming a stator for a dynamo-electric machine which comprises: a. forming a paramagnetic metal field core structure having pole portions defining lateral recesses for receiving field coils in supported relation and concave diametrically spaced cylindrical internal surfaces defining a space for receiving an armature; b. supporting said field core structure in a mold having convex surfaces defining narrow spaces around said recesses and convex internally cylindrical surfaces defining shroud form spaces at the axial ends of said pole portions, said convex internally cylindrical surfaces being diametrically spaced a distance greater throughout the major portion of their length than said spacing of said concave cylindrical internal surfaces; c. injecting a thermo plastic insulating material having an elastic memory into the spaces between said surfaces under conditions to form a unitary rigidified plastic covering thereabout having selected insulating surfaces and supporting structural surfaces conforming to said space and shrouds extending from said pole portions with their outer ends spaced radially outwardly from said cylindrical surfaces; and d. progressively winding turns of field coils in said recesses and over said shrouds under tension to progressively draw with the later turns the ends of the shrouds radially inwardly to a distance spaced approximately the same as the diameter of said concave armature receiving cylindrical surfaces and relieve the tension on preceeding turns in contact with said covering on said pole portions.

Claim 2

The method of forming a stator for a dynamo-electric machine which comprises: a. forming a paramagnetic metal field core structure having pole portions defining lateral recesses for receiving field coils in supported relation and concave diametrically spaced cylindrical internal surfaces defining a space for receiving an armature; b. supporting said field core structure in a mold having convex surfaces defining narrow spaces around said recesses and convex internally cylindrical surfaces defining shroud form spaces at the axial ends of said pole portions, said convex internally cylindrical surfaces being diametrically spaced a distance greater throughout the major portion of their length than said spacing of said concave cylindrical internal surfaces; c. injecting a thermo plastic insulating material having an elastic memory into the spaces between said surfaces under conditions to form a unitary rigidified plastic covering thereabout having selected insulating surfaces and supporting structural surfaces conforming to said space and shrouds extending from said pole portions with their outer ends spaced radially outwardly from said cylindrical surfaces; and d. progressively winding turns of field coils in said recesses and over said shrouds under tension to progressively draw with the later turns the ends of the shrouds radially inwardly to a distance spaced approximately the same as the diameter of said concave armature receiving cylindrical surfaces and relieve the tension on preceeding turns in contact with said covering on said pole portions.

Claim 3

The method of forming a stator for a dynamo-electric machine which comprises: a. providing a stack of paramagnetic sheet metal laminations comprising a field structure having transversely aligned edges defining recesses for receiving field coils in supported relation and cylindrical surfaces defining a space for receiving an armature; b. injection molding a thermoplastic insulating material intimately covering said edges defining said recesses and forming at the ends of the recesses shrouds extending from said lamination with their outer ends spaced radially outwardly from said cylindrical internal surfaces; and c. progressively winding turns of fiEld coils in said recesses and over said shrouds under tension to progressively draw by the later turns the ends of the shrouds radially inwardly to a spaced distance approximately the diameter of said cylindrical surfaces to relieve the tension on the earlier turns.

Claim 4

The method of forming a stator for a dynamo-electric machine which comprises: a. providing a stack of paramagnetic sheet metal laminations comprising a field structure having transversely aligned edges defining recesses for receiving field coils in supported relation and cylindrical surfaces defining a space for receiving an armature; b. injection molding a thermoplastic insulating material intimately covering said edges defining said recesses and forming at the ends of the recesses shrouds extending from said lamination with their outer ends spaced radially outwardly from said cylindrical internal surfaces; and c. progressively winding turns of fiEld coils in said recesses and over said shrouds under tension to progressively draw by the later turns the ends of the shrouds radially inwardly to a spaced distance approximately the diameter of said cylindrical surfaces to relieve the tension on the earlier turns.