Motor with stator made from linear core preform
First Claim
1. A method of making a stator assembly for a motor comprising:
- a) providing a linear stator core preform, wherein said core preform has a first end surface and a second end surface and poles extending along one side thereof;
b) winding wire around said poles to form windings;
c) forming a toroidal core by bringing the first end surface and the second end surface into contact with each other; and
d) substantially encapsulating said toroidal core and windings with a monolithic body of phase change material to form said stator assembly, the monolithic body of phase change material being the sole structure functioning to secure the core preform in the shape of the toroidal core.
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Accused Products
Abstract
A motor includes a stator having multiple conductors that create a plurality of magnetic fields when electrical current is conducted through the conductors. The stator has a pair of opposing end surfaces in contact with each other forming a toroidal core. A monolithic body of phase change material substantially encapsulates the conductors and holds said toroidal core in place. The stator is formed by laminating strips together to form a linear core preform, winding wire around poles extending from a side of the core preform, then rolling the preform to bring its two ends together to form the toroidal core. Hard disc drives using the motor, and methods of constructing the motor and hard disc drives are also disclosed.
164 Citations
26 Claims
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1. A method of making a stator assembly for a motor comprising:
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a) providing a linear stator core preform, wherein said core preform has a first end surface and a second end surface and poles extending along one side thereof;
b) winding wire around said poles to form windings;
c) forming a toroidal core by bringing the first end surface and the second end surface into contact with each other; and
d) substantially encapsulating said toroidal core and windings with a monolithic body of phase change material to form said stator assembly, the monolithic body of phase change material being the sole structure functioning to secure the core preform in the shape of the toroidal core. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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17. A method of making a motor comprising:
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a) providing a linear core preform having two end surfaces and a plurality of poles extending from one side;
b) winding wire around said poles;
c) forming a toroidal core by bringing the two end surfaces of the core preform adjacent to each other;
d) clamping said toroidal core in an injection mold cavity, the mold holding the core preform in the toroidal shape and bringing the two end surfaces into contact with each other;
e) injection molding phase change material around said toroidal core to substantially encapsulate said toroidal core with a monolithic body of phase change material to form a stator assembly, the monolithic body of phase change material structurally functioning to secure the core preform in the toroidal shape after the stator assembly is released from the mold; and
f) constructing the stator assembly into a motor. - View Dependent Claims (18, 19, 20, 21, 22)
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23. A method of making a stator assembly for a motor comprising:
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a) providing a linear stator core preform, wherein said core preform has a first end surface and a second end surface and poles extending along one side thereof;
b) winding wire around said poles to form windings;
c) forming a toroidal core by bringing the first end surface and the second end surface into contact with each other; and
d) substantially encapsulating said toroidal core and windings with a monolithic body of phase change material to form said stator assembly, the monolithic body of phase change material having a tensile strength of at least about 7,600 psi when tested under ASTM test method D638 and holding the core preform in a toroidal shape. - View Dependent Claims (24, 25, 26)
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Specification