SEGMENTED STATOR CORE

• US 20130002086A1
• Filed: 06/30/2011
• Published: 01/03/2013
• Est. Priority Date: 06/30/2011
• Status: Active Grant

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations LLC (General Motors Company)
• Inventors: Kaiser, Edward L., Savagian, Peter J., Bostwick, Peter
• Granted Patent: US 8,487,502 B2
• Time in Patent Office: Days
• US Class Current: 310/216.009
• CPC Class Codes: H02K 1/16 Stator cores with slots for windings

Abstract

A stator core includes a first lamination and a second lamination. The first lamination is formed from a plurality of first segments and has a plurality of first mounting ears. The second lamination is formed from a plurality of second segments and has a plurality of second mounting ears. The first lamination and the second lamination are aligned with a common axis and are rotated about the common axis such that the first lamination is not aligned with the second lamination.

Claims

1. A stator core, comprising:

a first lamination formed from a plurality of first segments, and having a plurality of first mounting ears;

a second lamination formed from a plurality of second segments, and having a plurality of second mounting ears; and

wherein the first lamination and the second lamination are aligned with a common axis and are rotated about the common axis such that the first lamination is not orthogonal relative to the second lamination.

2. The stator core of claim 1, wherein each of the first segments and the second segments further includes:

a body;

a first mounting tab extending from the body;

a second mounting tab extending from the body;

a plurality of teeth extending from the body opposite the first mounting tab and the second mounting tab;

wherein the first mounting tab and second mounting tab cooperate to form the first and second mounting ears; and

wherein the first mounting tab and second mounting tab cooperate to define a mounting slot, which is closed proximal to the body and open distal to the body.

3. The stator core of claim 2, wherein the mounting slot is configured to interface with a locating feature, and wherein first mounting tab and the second mounting tab do not fully surround the locating feature.

4. The stator core of claim 3, wherein each of the first segments and the second segments further includes:

a first end having a first joint; and

a second end having a second joint, wherein the second joint is configured to mate with the first joint.

5. The stator core of claim 4,

wherein the first mounting tab of the first segments is located on the first end adjacent the first joint;

and

wherein the second mounting tab of the first segments is located on the second end adjacent the second joint, such that the first mounting ears are formed adjacent to the first joint and the second joint.

6. The stator core of claim 5,

wherein the first mounting tab of the second segments is located between the first end and the second end;

and

wherein the second mounting tab of the second segments is located between the first end and the second end, such that the second mounting ears are located between the first end and the second end.

7. The stator core of claim 6, wherein the second mounting ears are located substantially equidistant from the first end and the second end of the second segments.

8. The stator core of claim 7, wherein the first joint of the first end substantially overlaps one of the teeth on the second end.

9. The stator core of claim 8, wherein the second lamination is rotated about the common axis by approximately forty to fifty degrees relative to the first lamination.

10. The stator core of claim 9, wherein each of the first segments and the second segments further includes:

a plurality of male interlocks; and

a plurality of female interlocks configured to mate with the male interlocks.

11. The stator core of claim 9, wherein each of the first segments and the second segments further includes a plurality of weld channels

12. A stator core, comprising:

a plurality of first laminations formed from a plurality of first segments having a plurality of first mounting ears;

a plurality of second laminations formed from a plurality of second segments having a plurality of second mounting ears;

wherein the first mounting ears and the second mounting ears define a plurality of mounting slots, which are closed proximal to the first segments and the second segments and open distal to the first segments and the second segments; and

wherein the first laminations and the second laminations are aligned with a common axis and are rotated about the common axis such that the first laminations are angularly offset relative to the second laminations.

13. The stator core of claim 12, wherein the mounting slots are configured to interface with a plurality of locating features, and wherein the mounting slots do not fully surround the locating features.

14. The stator core of claim 13, wherein each of the first segments and the second segments further includes:

a first end having a first joint; and

a second end having a second joint, wherein the second joint is configured to mate with the first joint.

15. The stator core of claim 14, wherein each of the first segments and the second segments further includes:

a body;

a first mounting tab extending from the body;

a second mounting tab extending from the body, wherein the first mounting tab and second mounting tab cooperate to form the first and second mounting ears; and

a plurality of teeth extending from the body opposite the first mounting tab and the second mounting tab.

16. The stator core of claim 15,

wherein the first mounting tab of the second segments is located between the first end and the second end;

and

wherein the second mounting tab of the second segments is located between the first end and the second end, such that the second mounting ears are located between the first end and the second end.

17. A stator core, comprising:

a plurality of first laminations formed from a plurality of first segments having a plurality of first mounting ears;

a plurality of second laminations formed from a plurality of second segments having a plurality of second mounting ears;

wherein the first mounting ears and the second mounting ears define a plurality of mounting slots, which are closed proximal to the first segments and the second segments and open distal to the first segments and the second segments;

wherein the first laminations and the second laminations are aligned with a common axis and are rotated about the common axis such that the first laminations are angularly offset relative to the second laminations; and

wherein each of the first segments and the second segments includes;

a body,

a first mounting tab extending from the body,

a second mounting tab extending from the body, wherein the first mounting tab and second mounting tab cooperate to form the first and second mounting ears,

wherein the first mounting tab of the second segments is located between the first end and the second end,

wherein the second mounting tab of the second segments is located between the first end and the second end, such that the second mounting ears are located between the first end and the second end, and

a plurality of teeth extending from the body opposite the first mounting tab and the second mounting tab.