Stator with molded encasement for small motors and manufacturing

Details Stator with molded encasement for small motors and manufacturing Stator with molded encasement for small motors and manufacturing

1999-05-25

2000-06-13

Ramirez, Nestor

Electrical generator or motor structure

Dynamoelectric

Rotary

310 43, 310179, 310258, 310259, 29596, 29598, H02K 100

Patent

active

060753048

ABSTRACT:
A stator has a lamination stack with a first electrically insulating layer and coil guides formed of high flow thermoplastic synthetic resin simultaneously insert-molded thereon. A coil is wound onto the stack and over the electrically insulating layer and the coil guides, and a second electrically insulating layer is molded over the coil to encase the coil. The second electrically insulating layer is formed of the high flow thermoplastic synthetic resin by injection molding. The method for producing the stator includes inserting the lamination stack into a first molding tool installed on an injection molding machine and injection molding onto the lamination stack the first insulation layer and the coil winding guides wherein the first insulation layer coats at least top and bottom surfaces and surfaces of slots of the lamination stack with thin resin skin insulation. The coil is then wound using insulated thin copper wire. The lamination stack is inserted into a second molding tool, having a gate disposed at a location where injected resin will not directly hit the coil, and the second insulator layer is then injection molded on the coil using the high flow thermoplastic synthetic resin injected at a filling pressure about 20 to 60% lower than a standard value for the high flow thermoplastic synthetic resin and at an injection speed more than twice as high as a standard injection speed for the high flow thermoplastic synthetic resin.

REFERENCES:
patent: 3710437 (1973-01-01), Kipple et al.
patent: 4825114 (1989-04-01), Ohtsuka et al.
patent: 5124607 (1992-06-01), Rieber et al.
patent: 5214839 (1993-06-01), Rieber et al.
patent: 5350960 (1994-09-01), Kiri et al.
patent: 5382859 (1995-01-01), Huang et al.
patent: 5490319 (1996-02-01), Nakamura et al.

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