Apparatus and method of encapsulating motors
First Claim
1. A method of encapsulating an inside out electric motor, the motor comprising a housing, a cylindrical permanent magnet rotor, and a cylindrical stator including associated motor control circuitry, the stator being concentrically within the rotor so as to define an annular air gap between the stator and the rotor, the method comprising:
- a. removing the permanent magnet rotor from the motor to produce a motor subassembly that includes all the electrically conductive components of the motor;
b. positioning a mold onto the motor subassembly including registering the mold with the housing so that the mold concentrically surrounds the motor subassembly with the inner surface of the mold adjacent the outer surface of the stator;
c. injecting a material into the mold to encapsulate all the electrically conductive components of the motor in the material, the inner surface of the mold preventing the injected material from encroaching beyond the outer surface of the stator and compromising the annular air gap; and
d. removing the mold from the motor subassembly.
4 Assignments
0 Petitions
Accused Products
Abstract
An apparatus and method of fabricating an electric motor encapsulates the major assemblies of the motor in protective encapsulating material. The method begins by assembling a blade and housing, a motor stator, a motor rotor and associated control circuitry into a complete electric fan. The operational characteristics of the complete fan are then tested to verify proper operation. The blade and rotor assemblies are then removed from the complete fan so that a mold may be positioned onto the fan. Encapsulating material is injected into the mold so as to encase the fan in the encapsulating material. The mold is removed and the blade and rotor assemblies are reinserted. Embodiments may use various encapsulating materials such as urethanes, silicones, or epoxies.
69 Citations
18 Claims
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1. A method of encapsulating an inside out electric motor, the motor comprising a housing, a cylindrical permanent magnet rotor, and a cylindrical stator including associated motor control circuitry, the stator being concentrically within the rotor so as to define an annular air gap between the stator and the rotor, the method comprising:
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a. removing the permanent magnet rotor from the motor to produce a motor subassembly that includes all the electrically conductive components of the motor; b. positioning a mold onto the motor subassembly including registering the mold with the housing so that the mold concentrically surrounds the motor subassembly with the inner surface of the mold adjacent the outer surface of the stator; c. injecting a material into the mold to encapsulate all the electrically conductive components of the motor in the material, the inner surface of the mold preventing the injected material from encroaching beyond the outer surface of the stator and compromising the annular air gap; and d. removing the mold from the motor subassembly. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A method of encapsulating an inside out electric motor, the motor comprising a housing, a cylindrical permanent magnet rotor, and a cylindrical stator including associated motor control circuitry, the stator being concentrically within the rotor so as to define an annular air gap between the stator and the rotor, the method comprising:
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a. positioning a mold on a portion of the motor including the stator and all the electrically conductive components of the motor, in registry with the portion of the motor so that the mold concentrically surrounds the portion of the motor with the inner surface of the mold adjacent the outer surface of the stator; b. injecting a material into the mold to encapsulate all the electrically conductive components of the motor in the material, the inner surface of the mold preventing the injected material from encroaching beyond the outer surface of the stator and compromising the annular air gap; and c. removing the mold from the portion of the motor. - View Dependent Claims (13, 14, 15, 16, 17, 18)
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Specification