Polyphenylene sulfide foam potted pole and coil assembly

Claim 2

An electromagnetic pole and coil assembly for a dynamo-electric machine comprising: a block of magnetizable metal defining a central pole piece for said assembly; a plurality of turns of wire forming a magnetizing coil for said pole, said coil circumscribing said pole piece and in spaced relation thereto so as to define an interspace therebetween; an electrically insulative polyphenylene sulfide coating covering said wire; and ground insulation substantially filling said interspace, said ground insulation comprising expanded-in-place high density polyphenylene sulfide foam constrictively engaging said pole piece and fused to said coating.

Claim 3

An electromagnetic pole and coil assembly for a dynamo-electric machine comprising: a block of magnetizable metal defining a central pole piece for said assembly, said pole piece having an outer surface including at least one depression therein; a plurality of turns of wire forming a magnetizing coil for sdid pole, said coil circumscribing said pole piece and in spaced relation to said surface so as to define an interspace therebetween; an electrically insulative polyphenylene sulfide coating covering said wire; ground insulation substantially filling said interspace and at least a portion of said depression, said ground insulation comprising expanded-in-place high density polyphenylene sulfide foam constrictively engaging said pole piece and fused to said coating.

Claim 4

An electromagnetic pole and coil assembly for a dynamo-electric machine comprising: a block of magnetizable metal defining a central pole piece for said assembly, said pole piece having an outer surface including at least one depression therein; a plurality of turns of wire forming a magnetizing coil for sdid pole, said coil circumscribing said pole piece and in spaced relation to said surface so as to define an interspace therebetween; an electrically insulative polyphenylene sulfide coating covering said wire; ground insulation substantially filling said interspace and at least a portion of said depression, said ground insulation comprising expanded-in-place high density polyphenylene sulfide foam constrictively engaging said pole piece and fused to said coating.

Claim 5

An electromagnetic pole and coil assembly for a dynamo-electric machine comprising: a block of magnetizable metal defining a central pole piece for said assembly, said pole piece having an outer surface engaging the assembly's ground insulation; a plurality of turns of wire forming a magnetizing coil for said pole, said coil circumscribing said pole piece and in spaced relation to said surface so as to define an interspace therebetween; an electrically insulative polyphenylene sulfide coating covering said wire; and ground insulation substantially filling said interspace, said ground insulation comprising expanded-in-place high density polyphenylene sulfide foam having strengthening glass fibers throughout, said foam constrictively engaging said pole piece and being fused to said coating.

Claim 6

An electromagnetic pole and coil assembly for a dynamo-electric machine comprising: a block of magnetizable metal defining a central pole piece for said assembly, said pole piece having an outer surface engaging the assembly's ground insulation; a plurality of turns of wire forming a magnetizing coil for said pole, said coil circumscribing said pole piece and in spaced relation to said surface so as to define an interspace therebetween; an electrically insulative polyphenylene sulfide coating covering said wire; and ground insulation substantially filling said interspace, said ground insulation comprising expanded-in-place high density polyphenylene sulfide foam having strengthening glass fibers throughout, said foam constrictively engaging said pole piece and being fused to said coating.

Claim 7

The assembly as claimed in claim 3 wherein said surface has at least one depression therein and said ground insulation at least partially fills said depression for anchoring said pole against axial displacement with respect to said coil.

Claim 8

An interpole for a dynamo-electric machine comprising: a block of magnetizable metal defining a central pole piece for said interpole; a plurality of edge-wound turns of wire forming a magnetizing coil for said pole, said coil circumscribing said pole piece and in spaced relation thereto so as to provide an interspace therebetween, said wire having a substantially rectangular cross-section; an electrically insulative polyphenylene sulfide coating covering said wire; a pole-side face on the inside of said coil adjacent said pole; an outside face on said coil opposite said pole-side face and generally defining the outer limits of the interpole; insulating means between said turns for spacing said turns one from the next so as to provide a cooling air gap between adjacent turns on said outside face of the coil and a foam-receiving gap between adjacent turns on said pole-side face of the coil; and ground insulation substantially filling said interspace and said foam-receiving gaps, said ground insulation comprising expanded-in-place high density polyphenylene sulfide foam constrictively engaging said pole piece and fused to said coating.

Claim 9

An interpole for a dynamo-electric machine comprising: a block of magnetizable metal defining a central pole piece for said interpole; a plurality of edge-wound turns of wire forming a magnetizing coil for said pole, said coil circumscribing said pole piece and in spaced relation thereto so as to provide an interspace therebetween, said wire having a substantially rectangular cross-section; an electrically insulative polyphenylene sulfide coating covering said wire; a pole-side face on the inside of said coil adjacent said pole; an outside face on said coil opposite said pole-side face and generally defining the outer limits of the interpole; insulating means between said turns for spacing said turns one from the next so as to provide a cooling air gap between adjacent turns on said outside face of the coil and a foam-receiving gap between adjacent turns on said pole-side face of the coil; and ground insulation substantially filling said interspace and said foam-receiving gaps, said ground insulation comprising expanded-in-place high density polyphenylene sulfide foam constrictively engaging said pole piece and fused to said coating.

Claim 10

An interpole for a locomotive traction motor comprising: a block of magnetizable metal defining a central pole piece for said assembly, said pole piece having an outer surface including at least one depression therein; a plurality of edge-wound turns of wire forming a magnetizing coil for said pole, said coil circumscribing said pole piece and in spaced relation to said surface so as to define an interspace therebetween, said wire having a substantially rectangular cross-section; an electrically insulative polyphenylene sulfide coating covering said wire; and ground insulation substantially filling said interspace and at least a portion of said depression, said ground insulation comprising expanded-in-place high density polyphenylene sulfide foam having strengthening glass fibers throughout, said foam constrictively engaging said pole piece and being fused to said coating.

Claim 11

An interpole for a locomotive traction motor comprising: a block of magnetizable metal defining a central pole piece for said assembly, said pole piece having an outer surface including at least one depression therein; a plurality of edge-wound turns of wire forming a magnetizing coil for said pole, said coil circumscribing said pole piece and in spaced relation to said surface so as to define an interspace therebetween, said wire having a substantially rectangular cross-section; an electrically insulative polyphenylene sulfide coating covering said wire; and ground insulation substantially filling said interspace and at least a portion of said depression, said ground insulation comprising expanded-in-place high density polyphenylene sulfide foam having strengthening glass fibers throughout, said foam constrictively engaging said pole piece and being fused to said coating.