Armature for an electromotive device

• US 6,111,329 A
• Filed: 03/29/1999
• Issued: 08/29/2000
• Est. Priority Date: 03/29/1999
• Status: Expired due to Term

• Current Assignee: ThinGap, Inc.
• Original Assignee: G&G Technologies Inc.
• Inventors: Graham, Gregory S., Yankie, Gerald W.
• Primary Examiner(s): LABALLE, CLAYTON E
• Application Number:
  US09/280,758
• Time in Patent Office: 519 Days
• Field of Search: 310/42, 310/40 MM, 310/261, 310/264, 310/DIG. 6, 29/598, 29/602.1, 29/605, 29/829, 29/831
• US Class Current: 310/12.02
• CPC Class Codes: H02K 13/04 Connections between commutator segments and windings
• CPC Class Codes: H02K 15/02 of stator or rotor bodies
• CPC Class Codes: H02K 15/12 Impregnating, heating or drying of windings, stators, rotors or machines
• CPC Class Codes: H02K 3/26 consisting of printed conductors
• CPC Class Codes: H02K 3/47 Air-gap windings, i.e. iron-free windings
• CPC Class Codes: Y10S 310/06 Printed-circuit motors and components
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49012 Rotor
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor
• CPC Class Codes: Y10T 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/49073 by assembling coil and core
• CPC Class Codes: Y10T 29/49146 with encapsulating, e.g., potting, etc.
• CPC Class Codes: Y10T 29/49169 Assembling electrical component directly to terminal or elongated conductor
• CPC Class Codes: Y10T 29/53839 having percussion or explosive operator

Abstract

An armature for an electric motor is constructed from a pair of precision machined copper plates cut in a pattern to produce a series of axially extending surface conductive bands with each band separated from the other by an insulated cutout. The precision machined plates are rolled to form two telescoping, hollow cylinders with each cylinder having a pattern of conductive bands representing a half-electric circuit. The outer surface of the inner cylinder is wrapped with several layers of fiberglass strands for structural stability and insulation. The fiberglass wrapped inner cylinder is telescoped inside the outer cylinder. The outer surface of the telescoped structure is also wrapped with several layers of fiberglass strands for structural stability. The conductive bands from the outer cylinder being the near mirror image of the conductive bands of the inner cylinder are helically coupled to form a complete electrical circuit. The resulting tubular structure is encapsulated in a potting material for further structural stability and insulation. The result is a freestanding ironless core inductive armature coil for a DC motor with brushes. The armature also has a commutator, which is mounted at one end of the coil and is in electrical contact with the helically coupled conductive bands. An insulated flywheel and shaft assembly is mounted inside the coil with the flywheel behind the commutator for motor mounting and operation.

Claims

1. A method of fabricating an inductive coil from a pair of conductive plates, comprising:

cutting each said plate in a pattern to produce a series of conductive bands and cutouts;

rolling said cut plates into telescoping inner and outer tubes;

wrapping said inner tube;

inserting said wrapped inner tube into said outer tube;

wrapping said outer tube; and

coupling said conductive bands of said inner tube to said conductive bands of said outer tube to form a helical inductive coil.

2. A method of fabricating a thin-walled inductive coil assembly from a pair of conductive plates, comprising:

cutting each said plate in a pattern to produce a series of conductive bands and cutouts;

rolling said cut plates into telescoping inner and outer tubes;

wrapping said inner tube;

inserting said wrapped inner tube into said outer tube;

wrapping said outer tube;

coupling said conductive bands of said inner tube to said conductive bands of said outer tube to form a helical inductive coil;

assembling a flywheel and coupling said flywheel and a commutator to said coil to form a coil assembly;

dipping said coil assembly;

centrifuging said dipped coil assembly in a potting material;

heating said centrifuged coil assembly at approximately 450 degrees F. to cure said potting material; and

cooling said heated coil assembly to room temperature.