Stator assembly made from a plurality of toroidal core segments and motor using same
First Claim
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1. A stator assembly, comprising:
- a) a plurality of stator arc segments forming a toroidal core, wherein each said stator arc segment has two end surfaces that are each in contact with an end surface of another stator arc segment to form the toroidal core; and
b) a monolithic body of phase change material substantially encapsulating the stator arc segments and holding said end surfaces in contact with one another.
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Abstract
A plurality of stator arc segments form a toroidal core for a stator assembly used to make a motor. In a preferred embodiment, a plurality of magnetic fields is created when electrical current is conducted through wire wound around poles on the toroidal core. A monolithic body of phase change material substantially encapsulates the conductors and holds the stator arc segments in contact with each other in the toroidal core. Hard disc drives using the motor, and methods of constructing the motor and hard disc drives are also disclosed.
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Citations
29 Claims
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1. A stator assembly, comprising:
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a) a plurality of stator arc segments forming a toroidal core, wherein each said stator arc segment has two end surfaces that are each in contact with an end surface of another stator arc segment to form the toroidal core; and
b) a monolithic body of phase change material substantially encapsulating the stator arc segments and holding said end surfaces in contact with one another. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 23)
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9. A method of making a stator assembly for a motor comprising:
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a) providing at least two stator arc segments each having a first end surface and a second end surface;
b) aligning said stator arc segments to form a toroidal core, wherein each said end surface of one segment is in contact with an opposing end surface of another segment; and
c) substantially encapsulating said toroidal core with a monolithic body of phase change material to form said stator assembly. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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21. A method of making a motor comprising:
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a) providing four stator arc segments, wherein each stator arc segment has a first end surface and a second end surface;
b) aligning said stator arc segments to form a toroidal core, wherein each said end surface of one segment is in contact with an opposing end surface of another segment;
c) substantially encapsulating said toroidal core with a monolithic body of phase change material, wherein said substantially encapsulating is by injection molding said phase change material around said toroidal core to form a stator assembly; and
d) constructing the stator assembly into a motor. - View Dependent Claims (22, 24, 25, 26, 28)
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27. A combination of stator arc segments and a carrier used to support said stator arc segments during a winding operation comprising:
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a) a plurality of stator arc segments; and
b) a plurality of cavities to hold and support said stator arc segments.
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29. A stator arc segment comprising a plurality of steel laminations and at least one pole.
Specification