Split stator of electric motor

• US 7,696,667 B2
• Filed: 11/02/2006
• Issued: 04/13/2010
• Est. Priority Date: 11/21/2005
• Status: Expired due to Fees

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Tatebe, Katuhiko
• Primary Examiner(s): NGUYEN, HANH N
• Application Number:
  US11/555,898
• Publication Number:
  US 20070114878A1
• Time in Patent Office: 1,258 Days
• Field of Search: 310/259, 310/216, 310/218, 310/43
• US Class Current: 310/216.102
• CPC Class Codes: H02K 1/148 Sectional cores H02K1/141 takes precedence
• CPC Class Codes: H02K 3/18 Windings for salient poles
• 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

Abstract

A stator of an electric motor is formed by a plurality of split stators that are divided in a circumferential direction of the cylindrical stator. Each split stator comprises a yoke portion that is divided in the circumferential direction, a tooth portion that extends from the yoke portion a in a radial direction, and a coil wound on the tooth portion. The coil is pressed into the coil-housing portion, defined by the yoke portion and the tooth portion, by a press die. While the coil is pressed into the coil-housing portion by the press die, the coil may be covered by, for example, being integrated with a resin. Thus, the risk of damaging the coating of the coil is significantly reduced, the coil density is improved, and good circularity of the stator is ensured.

Claims

1. A split stator for an electric motor comprising:

a yoke portion that is divided in a circumferential direction of a cylindrical stator of the electric motor,

a tooth portion that extends from the yoke portion in a radial direction of the cylindrical stator, and

a coil wound on the tooth portion,

wherein the coil is housed in a coil-housing portion defined by the yoke portion and the tooth portion and is covered with a cover that covers the coil-housing portion, and the cylindrical stator is formed by a plurality of split stators that are divided in a circumferential direction of the cylindrical stator,

wherein a recessed portion is formed at an end surface of the cover, in the circumferential direction, and when the split stators are combined, the coils of adjacent split stators are separated, in the circumferential direction, by a void space formed by the recessed portions, and

wherein the cover comprises a resin and the coil is integrated with the resin.

2. The split stator of the electric motor according to claim 1, further comprising an insulation material, provided in the void space between the coils of adjacent split stators.

3. The split stator of the electric motor according to claim 2, wherein the insulation material comprises a paste.

4. A method of producing a split stator of the electric motor as recited in claim 1, comprising:

winding a predetermined amount of the coil on the tooth portion up to an outside of the coil housing portion;

pressing the coil wound on the tooth portion up to the outside of the coil housing portion into the coil housing portion by a press die; and

integrating the coil with a resin by injecting the resin into the coil housing portion while the coil is pressed into the coil housing portion by the press die.

5. The split stator of the electric motor according to claim 1, wherein the resin is an epoxy resin.

6. The split stator of the electric motor according to claim 1, wherein resin on a first side of the recessed portion is directly exposed to resin on a second side of the recessed portion that is opposite the first side.