Method of manufacturing dynamoelectric machines

• US 3,874,073 A
• Filed: 07/11/1973
• Issued: 04/01/1975
• Est. Priority Date: 01/06/1972
• Status: Expired due to Term

• Current Assignee: Michael E. Wendt, Richard W. Dochterman
• Original Assignee: Michael E. Wendt, Richard W. Dochterman
• Inventors: Dochterman, Richard W., Wendt, Michael E.
• Primary Examiner(s): Hall, Carl E.
• Application Number:
  US05/378,191
• Time in Patent Office: 629 Days
• Field of Search: 29/596,598 310/42-43,87,89 264/272 174/52.6
• US Class Current: 29/598
• CPC Class Codes: H02K 15/12 Impregnating, heating or drying of windings, stators, rotors or machines
• CPC Class Codes: H02K 15/16 Centering rotors within the stator; Balancing rotors
• CPC Class Codes: H02K 3/32 Windings characterised by the shape, form or construction of the insulation
• CPC Class Codes: H02K 5/08 Insulating casings
• CPC Class Codes: Y10T 29/49012 Rotor

Abstract

Composite structure includes winding support with windings accommodated thereon and a housing means that does not include a metal case or shell and that does include a substantially rigid primary structural member formed of an interstitial mass of inert particulate material. Resinous material occupies interstices of interstitial mass and bonds inert particles together and to remainder of the structure. Improved composite structure exhibits enhanced structural integrity, corrosion resistance and, even when employing refractory material such as sand as the particulate material, exhibits measurably improved heat dissipation characteristics. Methods of making composite structures including a particulate interstitial mass and dynamoelectric machines including such structures.

Claims

1. A method of manufacturing a dynamoelectric machine having at least a rotatable member and a stationary composite structure comprising a winding support, at least one winding accommodated by the winding support, and a self-supporting primary structural member forming a housing for protecting at least part of the one winding, said method comprising:

forming the self-supporting primary structural member as a substantially rigid, selfsupporting, exterior housing member around at least part of the winding without an exterior peripheral casing therearound by placing at least the part of the one winding in a mold cavity, by packing within the mold cavity from about 65 to about 80 parts by weight of an interstitial mass of particulate material comprising at least about 50% by weight of from 40 to 100 mesh size particles around said part of the one winding and retaining from about 20 to about 35 parts by weight of an unhardened material in the interstices of the mass, and by hardening the unhardened material to form the primary structural member as a substantially rigid housing member around said part of the one winding;

removing the housing member and part of the one winding from the mold cavity; and

thereafter supporting the rotatable member for rotation relative to the composite structure.

2. The method of claim 1 wherein paCking an interstitial mass of particulate material around part of the one winding and retaining an unhardened material in the interstices of the mass includes packing a mass of relatively dry particulate material around said part of the one winding, and thereafter permeating the mass of particulate material with a fluid resinous material.

3. The method of claim 1 wherein packing an interstitial mass of particulate material around part of the one winding and retaining an unhardened material in the interstices of the mass includes substantially simultaneously forcing particulate material and resinous material against at least part of the winding support and said part of the one winding.

4. A method of manufacturing a dynamoelectric machine comprising a rotor;

a stationary composite structure having a stator assembly and housing means for at least part of the stator assembly; and

at least one bearing system mounting the stator assembly and the rotor for relative rotation, the method comprising;

forming, around at least part of the stator assembly, the housing means so as to be self-supportable without a peripheral covering therearound by positioning at least part of the stator assembly in a mold, by positioning an interstitial mass of from about 65 to about 80 parts by weight of particles of particulate material having an A.F.S. grain fineness number greater than 45 and from about 20 to about 35 parts by weight of a resinous material within the interstices of the mass around at least said part of the stator assembly, and by hardening the resinous material to secure the particles of particulate material together and to at least part of the stator assembly to form at least a portion of the housing means, removing the stationary composite structure so formed from the mold; and

positioning the rotor relative to the stator assembly and securing the at least one bearing system to the housing means.

5. The method set forth in claim 4 wherein positioning the rotor relative to the stator assembly and securing the at least one bearing system to the housing means includes positioning the rotor relative to the stator assembly to establish a predetermined air gap between the rotor and a selected portion of the stator assembly, securing the rotor in substantially fixed relation to the stator assembly in a substantially stress-free condition by depositing an unhardened adhesive material along at least a portion of the interface of said portion of the housing means and the at least one bearing system, and thereafter hardening the adhesive material.

6. The method set forth in claim 4 wherein positioning the rotor relative to the stator assembly and securing the at least one bearing system to the housing means includes applying an uncured thermo-responsive material to at least one surface at the interface between the bearing system and the housing means, and thereafter hardening the thermo-responsive material.

7. A method of manufacturing a dynamoelectric machine comprising a rotor;

a stationary composite structure having a stator assembly and housing means for at least part of the stator assembly; and

at least one bearing system mounting the stator assembly and the rotor for relative rotation, the method comprising the steps of;

positioning at least part of the stator assembly in a mold;

positioning an interstitial mass of from about 65 to about 80 parts by weight of particles of particulate material and from about 20 to about 35 parts by weight of a resinous material within the interstices of the mass around at least said part of the stator assembly;

hardening the resinous material to secure the particles of particulate material together and to at least said part of the stator assembly to form an impact resistant substantially rigid mass and thereby establishing a self-supporting substantially rigid housing member without need for a peripheral metallic covering;

removing the resulting stationary composite structure fRom the mold; and

positioning the rotor relative to the stator assembly, securing the at least one bearing system to the housing means, and supporting the rotor relative to the stator assembly with at least the at least one bearing system.

8. The method set forth in claim 7 wherein securing the at least one bearing system to the housing means includes applying an uncured thermo-responsive material to at least one surface at the interface between the bearing system and the housing means and thereafter hardening the thermo-responsive material.