Stator for brushless motor

• US 20040020027A1
• Filed: 08/05/2002
• Published: 02/05/2004
• Est. Priority Date: 08/05/2002
• Status: Active Grant

• Current Assignee: Visteon Global Technologies Incorporated (Visteon Corporation)
• Original Assignee: Visteon Global Technologies Incorporated (Visteon Corporation)
• Inventors: Shiah, Kyi-Shin
• Granted Patent: US 6,935,011 B2
• Time in Patent Office: Days
• US Class Current: 29/596
• CPC Class Codes: H02K 1/146 consisting of a generally annular yoke with salient poles
• CPC Class Codes: H02K 1/148 Sectional cores H02K1/141 takes precedence
• CPC Class Codes: H02K 15/022 with salient poles or claw-shaped poles
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49012 Rotor
• CPC Class Codes: Y10T 29/49073 by assembling coil and core
• CPC Class Codes: Y10T 29/49078 Laminated

Abstract

A method of forming a stator for a brushless motor comprising providing a stator core having a generally rectangular body and having a plurality of teeth extending generally perpendicularly from a side of the body, and forming the stator core into a generally circular shape.

Claims

1. A method of forming a stator for a brushless motor comprising:

providing a stator core having a generally rectangular body and having a plurality of teeth extending generally perpendicularly from a side of the body; and

forming the stator core into a generally circular shape.

2. The method according to claim 1 further including placing a coil of electrical wire around each of the teeth prior to forming the stator core into a generally circular shape.

3. The method according to claim 2 wherein forming the stator core into a generally circular shape includes bending the body of the stator core in the direction of the extending teeth such that all the teeth extend toward a center of the generally circular shape.

4. The method of claim 3 wherein each of the teeth include a tip portion having extending flanges and wherein bending the body of the stator core in the direction of the extending teeth includes bending the body of the stator core in the direction of the extending teeth until the extending flanges of the tip portions contact the extending flanges of adjacent teeth.

5. The method according to claim 2 wherein placing a coil of electrical wire around each of the teeth includes wrapping the electrical wire around each tooth.

6. The method according to claim 2 wherein placing a coil of electrical wire around each of the teeth includes forming a plurality of coils of electrical wire and placing one of the plurality of coils on each of the teeth.

7. The method according to claim 1 wherein forming the stator core into a generally circular shape includes bending the body of the stator core away from extending teeth such that all the teeth extend outward radially.

8. The method according to claim 7 further including placing a coil of electrical wire around each of the teeth after forming the stator core into a generally circular shape.

9. The method according to claim 8 further including:

providing an outer piece which is generally cylindrical in shape and includes a plurality of recesses formed within an inner surface thereof, each of the teeth having a tip portion and each of the recesses adapted to receive the tip portion of one of the teeth; and

securing the stator core within the outer piece wherein each of the tip portions of the teeth is received within one of the recesses formed within the inner surface of the outer piece.

10. The method according to claim 9 wherein the tip portions of the teeth define an outer diameter of the stator core and the recesses define an inner diameter, wherein the inner diameter of the recesses is smaller than the outer diameter of the tip portions of the teeth and securing the stator core within the outer piece includes press-fitting the stator core within the outer piece such that there is an interference fit between the recesses and the tip portions of the teeth, whereby the stator core is frictionally held within the outer piece.

11. The method according to claim 9 wherein the tip portions of the teeth define an outer diameter of the stator core and the recesses define an inner diameter, wherein the inner diameter of the recesses is smaller than the outer diameter of the tip portions of the teeth and securing the stator core within the outer piece includes heating the outer piece such that the outer piece expands to a point where the inner diameter of the recesses is larger than the outer diameter of the tip portions, placing the stator core within the outer piece such that the tip portions of the teeth are aligned with the recesses of the outer piece, and allowing the outer piece to cool such that the outer piece shrinks to a point where the inner diameter of the recesses is smaller than the outer diameter of the tip portions, whereby the stator core is frictionally held within the outer piece.

12. The method according to claim 9 wherein the tip portions of the teeth define an outer diameter of the stator core and the recesses define an inner diameter, wherein the inner diameter of the recesses is slightly larger than the outer diameter of the tip portions of the teeth and securing the stator core within the outer piece includes placing the stator core within the outer piece such that the tip portions of the teeth are aligned with the recesses of the outer piece and deforming the outer piece to reduce the inner diameter of the recesses, whereby the stator core is frictionally held within the outer piece.

13. The method according to claim 12 wherein the outer piece includes a plurality of crimp zones which are adapted to allow the outer piece to be deformed to a smaller size.

14. The method according to claim 9 wherein said outer piece comprises a plurality of arcuate sections and securing the stator core within the outer piece includes placing the arcuate sections adjacent one another such that the arcuate sections encircle the stator core and attaching the arcuate sections to one another such that the stator core is frictionally held therein.

15. The method according to claim 14 wherein attaching the arcuate sections to one another includes welding each arcuate section to the adjacent arcuate sections on either side.