Electric motor having a field assembly with slot insulation

• US 7,528,520 B2
• Filed: 10/04/2006
• Issued: 05/05/2009
• Est. Priority Date: 09/05/2003
• Status: Active Grant

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Verbrugge, Brandon L., Smith, David J., Kusmierski, Robert G., Du, Hung T., Zemlok, Michael A., Ortt, Earl M., Agnes, Michael J.
• Primary Examiner(s): NGUYEN, HANH N
• Application Number:
  US11/542,826
• Publication Number:
  US 20070024151A1
• Time in Patent Office: 944 Days
• Field of Search: 310/215, 310/216, 310/217, 310/218
• US Class Current: 310/216.025
• CPC Class Codes: H02K 1/148 Sectional cores H02K1/141 takes precedence
• 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 15/0435 Wound windings
• 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 3/325 for windings on salient poles, such as claw-shaped poles
• CPC Class Codes: H02K 3/522 for generally annular cores with salient poles
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49012 Rotor
• 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 29/53143 Motor or generator

Abstract

An electric motor has a field assembly, such as a stator, for a dynamoelectric machine has field coils that are wound to a net shape. Lead wires are brought out from the ends of each field coil. The field coils are insulated with insulating sleeves or insulating slot liners. The field coils are assembled with stator core pieces, such as pole pieces and return path pieces, into the stator. The stator core pieces are formed prior to being assembled with the field coils. In an aspect of the invention, the pole pieces and return path pieces are separately formed and then assembled together with the field coils, which have also been separately formed.

Claims

1. An electric motor, comprising a stator and an armature in the stator, the stator including:

a. separately formed pole pieces and return path pieces mated together;

b. field coils disposed on the pole pieces between the pole pieces and the return path pieces mated to the pole pieces; and

c. each portion of each field coil disposed between the pole piece on which the field coil is disposed and one of the return path pieces mated to that pole piece wrapped with an insulating slot liner made of a layer of insulation material with at least one of a B-stage thermosetting adhesive and a thermoplastic adhesive on at least one surface, the adhesive activated by heat during the assembly of the stator and bonding the insulation material to the field coil and the pole piece and return path piece to secure them together.

2. The motor of claim 1 wherein the insulation material has the adhesive on front and back surfaces.

3. A hand-held power tool, comprising a housing surrounding a motor, the motor including a stator and an apparatus in the stator, the stator including:

a. separately formed pole pieces and return path pieces mated together;

b. field coils disposed on the pole pieces between the pole pieces and the return path pieces mated to the pole pieces; and

c. each portion of each field coil disposed between the pole piece on which the field coil is disposed and one of the return path pieces mated to that pole piece wrapped with a insulating slot liner made of a layer of insulation material with at least one of a B-stage thermosetting adhesive and a thermoplastic adhesive on at least one surface, the adhesive activated by heat during the assembly of the stator and bonding the insulation material to the field coil and the pole piece and return path piece to secure them together.

4. The hand-held power tool of claim 3 wherein the insulation material has the adhesive on front and back surfaces.