Stator for a high efficiency motor and manufacturing methods thereof

Patent metadata

Field	Value
Publication number	US-10547232-B2
Application number	US-201615374800-A
Country	US
Kind code	B2
Filing date	Dec 9, 2016
Priority date	Oct 21, 2016
Publication date	Jan 28, 2020
Grant date	Jan 28, 2020

Abstract

A stator for a high efficiency motor and a manufacturing method of a stator for a high efficiency motor are disclosed. The method includes: preparing filling powder by coating a surface of soft magnetic powder with an insulating layer; providing a stator core partitioned into a center hole and inner spaces, the stator core including a yoke portion and a plurality of teeth; coiling coils around the plurality of teeth located in the inner spaces, respectively; and filling the inner spaces with a mixture of the filling powder and an adhesive, and curing the mixture of the filling powder and the adhesive.

First claim

What is claimed is:

1. A manufacturing method of a stator for a high efficiency motor, the method comprising:
preparing a filling powder by coating a surface of a soft magnetic powder with an insulating layer;
providing a stator core partitioned into a center hole and inner spaces, the stator core including a yoke portion and a plurality of teeth;
coiling coils around the plurality of teeth located in the inner spaces, respectively;
filling the inner spaces with a mixture of the filling powder and an adhesive; and
curing the mixture of the filling powder and the adhesive,
wherein the preparing of the filling powder includes
mixing the soft magnetic powder, an insulation powder, and a reaction accelerator together, therein providing a first mixture powder,
milling the first mixture powder so that the insulation powder adheres to the surface of the soft magnetic powder, therein providing a second mixture powder, and
heat-treating the second mixture powder so that the insulating layer is formed on the surface of the soft magnetic powder, therein providing the filling powder.

2. The method of claim 1 , wherein the insulation powder is alumina powder, and
wherein the reaction accelerator is ammonium chloride powder.

3. The method of claim 2 , wherein the first mixture powder is prepared by mixing the soft magnetic powder, the alumina powder, and the ammonium chloride powder at a mass ratio of 60-90:9-39:1, respectively.

4. The method of claim 3 , wherein the second mixture powder is heat-treated at a temperature of 750-1300° C. for 10-24 hours.

5. The method of claim 4 , further comprising:
forming core covers by applying the mixture to upper and lower surfaces of the stator core filled with the mixture, and by curing the mixture after the filling of the inner spaces.

6. The method of claim 2 , wherein the second mixture powder is heat-treated at a temperature of 750-1300° C. for 10-24 hours.

7. The method of claim 1 , wherein the second mixture powder is heat-treated at a temperature of 750-1300° C. for 10-24 hours.

8. The method of claim 1 , further comprising:
forming core covers by applying the mixture to upper and lower surfaces of the stator core filled with the mixture, and by curing the mixture after the filling of the inner spaces.

9. The method of claim 1 , the stator core is provided in such a way that a plurality of split cores having respective back yokes and teeth is radially disposed to form the center hole and the inner spaces.

Assignees

• Hyundai Motor Co Ltd

Inventors

• Kim Young Min

Classifications

• H02K1/148

  Sectional cores (H02K1/141 takes precedence) · CPC title

• H02K1/02

  characterised by the magnetic material · CPC title

• H02K15/12 Primary

  Impregnating, moulding insulation, heating or drying of windings, stators, rotors or machines · CPC title

• H02K15/022 Primary

  with salient poles · CPC title

• H02K3/18

  Windings for salient poles · CPC title