MOTOR

• US 20070103011A1
• Filed: 12/22/2006
• Published: 05/10/2007
• Est. Priority Date: 07/29/1999
• Status: Abandoned Application

• Current Assignee: Nytell Software LLC (Intellectual Ventures LLC)
• Original Assignee: Encap Technologies, Inc. (Encap Holding Company), Encap Motor Corporation
• Inventors: NEAL, GRIFFITH
• Application Number:
  US11/615,795
• Publication Number:
  US 20070103011A1
• Time in Patent Office: Days
• US Class Current: 310/67.R
• CPC Class Codes: G11B 19/2009 Turntables, hubs and motors for disk drives; Mounting of motors in the drive means for clamping of disk to turntable G11B17/022 and subgroups
• CPC Class Codes: H02K 1/04 characterised by the material used for insulating the magnetic circuit or parts thereof
• CPC Class Codes: H02K 1/146 consisting of a generally annular yoke with salient poles
• CPC Class Codes: H02K 1/18 Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• CPC Class Codes: H02K 1/182 to stators axially facing the rotor, i.e. with axial or conical air gap
• CPC Class Codes: H02K 1/185 to outer stators
• CPC Class Codes: H02K 1/187 to inner stators
• CPC Class Codes: H02K 11/00 Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection casings, enclosures or supports H02K5/00
• CPC Class Codes: H02K 11/33 Drive circuits, e.g. power electronics H02K11/38 takes precedence
• CPC Class Codes: H02K 15/10 Applying solid insulation to windings, stators or rotors
• CPC Class Codes: H02K 15/12 Impregnating, heating or drying of windings, stators, rotors or machines
• CPC Class Codes: H02K 15/14 Casings; Enclosures; Supports
• CPC Class Codes: H02K 15/16 Centering rotors within the stator; Balancing rotors
• CPC Class Codes: H02K 21/16 having annular armature cores with salient poles with homopolar co-operation H02K21/20
• CPC Class Codes: H02K 21/22 with magnets rotating around the armatures, e.g. flywheel magnetos
• CPC Class Codes: H02K 21/24 with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• CPC Class Codes: H02K 2211/03 Machines characterised by circuit boards, e.g. pcb
• CPC Class Codes: H02K 3/38 around winding heads, equalising connectors, or connections thereto
• CPC Class Codes: H02K 3/46 Fastening of windings on the stator or rotor structure
• CPC Class Codes: H02K 3/47 Air-gap windings, i.e. iron-free windings
• CPC Class Codes: H02K 5/02 : Casings or enclosures characterised by the material thereof
• CPC Class Codes: H02K 5/08 : Insulating casings
• CPC Class Codes: H02K 5/1672 : radially supporting the rotary shaft at both ends of the rotor H02K5/1677 takes precedence
• CPC Class Codes: H02K 5/1675 : radially supporting the rotary shaft at only one end of the rotor H02K5/1677 takes precedence
• CPC Class Codes: H02K 5/1677 : radially supporting the rotor around a fixed spindle; radially supporting the rotor directly
• CPC Class Codes: H02K 5/1732 : radially supporting the rotary shaft at both ends of the rotor H02K5/1737 takes precedence
• CPC Class Codes: H02K 5/1735 : radially supporting the rotary shaft at only one end of the rotor H02K5/1737 takes precedence
• CPC Class Codes: H02K 5/225 : Terminal boxes or connection arrangements specially adapted for submersible motors H02K5/132
• CPC Class Codes: H02K 5/24 : specially adapted for suppression or reduction of noise or vibrations
• CPC Class Codes: H02K 7/083 : radially supporting the rotary shaft at both ends of the rotor H02K7/086, H02K7/09 take precedence
• CPC Class Codes: H02K 7/085 : radially supporting the rotary shaft at only one end of the rotor H02K7/086, H02K7/09 take precedence
• CPC Class Codes: H02K 7/086 : radially supporting the rotor around a fixed spindle; radially supporting the rotor directly H02K7/09 takes precedence
• CPC Class Codes: H02K 7/088 : radially supporting the rotor directly
• CPC Class Codes: H02K 7/09 : with magnetic bearings
• CPC Class Codes: H02K 7/14 : Structural association with mechanical loads, e.g. with hand-held machine tools or fans with fan or impeller for cooling the machine H02K9/06
• CPC Class Codes: Y10T 29/49009 : Dynamoelectric machine
• CPC Class Codes: Y10T 29/49012 : Rotor

Abstract

A motor has a stator substantially encapsulated within a body of thermoplastic material. A plurality of different motors are made by encapsulating different stators using the same mold tool. The stators may differ with respect to one or more of the following: i) the number of turns of wire per winding, ii) the number of poles, iii) the diameter of the stator, and iv) the thickness of the stator The stators are then used to build motors with different characteristics. The process produces benefits associated with development time and cost for new motor configurations.

Claims

1. A method of manufacturing a variety of motors comprising:

a) providing a plurality of stators having poles with windings thereon, the stators differing from one another in one or more of the properties of;

i) the number of turns of wire per winding;

ii) the number of poles;

iii) the diameter of the stator; and

iv) the thickness of the stator;

b) providing a common mold tool;

c) holding a first stator in the mold tool and adding a phase change material to substantially encapsulate the first stator;

d) using the encapsulated stator, a bearing and a shaft to build a first variety of motor;

e) holding a second stator having properties different than the first stator in said mold and adding a phase change material to substantially encapsulate the second stator; and

f) using the encapsulated second stator, a bearing and a shaft to build a second variety of motor.

2. The method of claim 1 wherein the phase change material is different for the first and second stators.

3. The method of claim 1 wherein the phase change material completely encases the stator so that no external surfaces are exposed.

4. The method of claim 1 wherein the stator is constructed into a fluid pump.

5. The method of claim 1 wherein the stator is constructed into a generator.

6. A method of manufacturing a variety of motors comprising:

a) providing a plurality of rotors having poles with windings thereon, the rotors differing from one another in one or more of the properties of;

i) the number of turns of wire per winding;

ii) the number of poles;

iii) the diameter of the rotor; and

iv) the thickness of the rotor;

b) providing a common mold tool;

c) holding a first rotor in the mold tool and adding a phase change material to substantially encapsulate the first rotor;

d) using the encapsulated rotor, a bearing and a shaft to build a first variety of motor;

e) holding a second rotor having properties different than the first stator in said mold and adding a phase change material to substantially encapsulate the second rotor; and

f) using the encapsulated second rotor, a bearing and a shaft to build a second variety of motor.

7. The method of claim 6 where the phase change material is different for the first and second rotors.

8. The method of claim 6 wherein the phase change material completely encases the rotor so that no external surfaces are exposed.

9. The method of claim 6 wherein the stator is constructed into a fluid pump.

10. The method of claim 6 wherein the stator is constructed into a generator.

11. A plurality of motors comprising first and second motors, each motor comprising a stator having poles with windings thereon and a phase change material substantially encapsulating the stator, the phase change material having been molded in a common mold tool for all motors in the plurality of motors, the motors also each comprising at least one bearing and a shaft, the stators in the first and second motors differing from one another in one or more of the properties of:

i) the number of turns of wire per winding;

ii) the number of poles;

iii) the diameter of the stator; and

iv) the thickness of the stator.

12. The plurality of motors of claim 11 wherein the phase change material is different for the stators in the first motors compared to the stators in the second motors.

13. The plurality of motors of claim 11 wherein the phase change material completely encases the stator so that no external surfaces are exposed.