Methods of manufacturing a stator core for a brushless motor

• US 8,479,378 B1
• Filed: 02/09/2012
• Issued: 07/09/2013
• Est. Priority Date: 02/09/2012
• Status: Active Grant

• Current Assignee: John Pairaktaridis
• Original Assignee: John Pairaktaridis
• Inventors: Pairaktaridis, John
• Primary Examiner(s): TRINH, MINH N
• Application Number:
  US13/369,518
• Time in Patent Office: 516 Days
• Field of Search: 29596-598, 295641-5642, 297/32, 310/67.R, 310/71, 310/89, 310/216.009, 310/216.043, 264/272.2
• US Class Current: 29/596
• CPC Class Codes: H02K 1/148 Sectional cores H02K1/141 takes precedence
• CPC Class Codes: H02K 15/02 of stator or rotor bodies
• CPC Class Codes: H02K 15/022 with salient poles or claw-shaped poles
• CPC Class Codes: H02K 15/095 by laying conductors around salient poles
• CPC Class Codes: H02K 15/12 Impregnating, heating or drying of windings, stators, rotors or machines
• CPC Class Codes: Y02P 80/30 Reducing waste in manufacturing processes; Calculations of released waste quantities
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49071 by winding or coiling
• CPC Class Codes: Y10T 29/53143 Motor or generator

Abstract

Method of manufacturing a stator core includes stacking a plurality of substantially T-shaped teeth obtained from a jigsaw pattern of said teeth into a plurality of stacks. In each said stack, said teeth are substantially aligned with each other. Said method includes winding said stacks with a plurality of windings and placing said stacks along the perimeter of a polygonal outer surface of a ferromagnetic tube having an inner channel. Each side of said outer surface corresponds to each said stack and contacts the bases of said legs of each said stack. Said method includes inserting said stacks and said tube into an inner space defined by an annular inner surface of a mold and a shaft into said channel. Said stacks are stationed along the circumference of said inner surface. Said method includes vacuum encapsulating said inner space in epoxy resin and removing said mold and shaft.

Claims

1. A method of manufacturing a stator core, said method comprising:

stacking a plurality of teeth into a plurality of stacks, wherein said teeth are obtained from a jigsaw pattern of said teeth, said teeth are substantially identical to each other in size, each said tooth is substantially T-shaped as defined by two arms protruding sideways from a leg, in each said stack said teeth are substantially aligned with each other;

winding said stacks with a plurality of windings;

placing said stacks along the perimeter of a polygonal outer surface of a ferromagnetic tube having an inner channel extending therethrough, wherein each side of said outer surface corresponds to each said stack and contacts the bases of said legs of each said stack;

inserting said stacks and said tube into an inner space defined by an annular inner surface of a mold and a shaft into said channel, wherein said stacks are stationed along the circumference of said inner surface, the top surfaces of the arms face said inner surface;

vacuum encapsulating said inner space in an epoxy resin; and

removing said mold and said shaft.

2. The method of claim 1, wherein said pattern defines at least a portion of a sheet, at least one of said teeth includes a soft magnetic alloy, at least one of said windings is a coil or a belt and each said winding corresponds to each said stack.

3. The method of claim 2, wherein said portion is formed by cuffing, said annular inner surface includes a plurality of separators, at least one of said windings is laminated and each said separator is stationed between two of said stacks.

4. The method of claim 3, wherein said shaft is connected to a base, said separators extend in parallel along said annular inner surface, said cuffing includes waterjet cuffing.

5. The method of claim 4, wherein the outer surface of said mold is polygonal, said mold includes paraffin or aluminum.

6. The method of claim 5, wherein said base is connected to said mold, said stacks have a substantially identical height.