Molded core assemblies for a motor-generator

Patent metadata

Field	Value
Publication number	US-10923969-B2
Application number	US-201916247521-A
Country	US
Kind code	B2
Filing date	Jan 14, 2019
Priority date	Jan 14, 2019
Publication date	Feb 16, 2021
Grant date	Feb 16, 2021

Abstract

Systems, methods and motor-generators with preform windings and a molded core are described. The preform windings include a first end, a second end, and a plurality of in-slot portions extending from the first end to the second end. The molded core includes a plurality of slots. Each of the plurality of slots including a respective in-slot portion disposed therein. Each of the plurality of slots includes a wall conforming to an outer profile of the respective in-slot portion.

First claim

What is claimed is:

1. An assembly for a motor-generator, the assembly comprising:
preform windings including a first end, a second end, and a plurality of in-slot portions, the plurality of in-slot portions extending from the first end to the second end; and
a molded core including a plurality of slots, each of the plurality of slots including a respective in-slot portion of the plurality of in-slot portions disposed therein, each of the plurality of slots including a wall conforming to an outer profile of the respective in-slot portion;
wherein the molded core is a molded stator core, the assembly further comprises at least one of a housing or a portion of a stator-mounting assembly, the at least one of the housing or the portion of the stator-mounting assembly is a portion of a mold used to form the molded stator core.

2. The assembly of claim 1 , wherein the molded core is formed from a curable material including a resin and a ferromagnetic filler.

3. The assembly of claim 2 , wherein the ferromagnetic filler is ferrosilicon.

4. The assembly of claim 1 , wherein the at least one of the housing or the portion of the stator-mounting assembly is attached to the molded stator core using a mechanical interlock.

5. The assembly of claim 1 , further comprising a plurality of stator teeth, each of the plurality of stator teeth being disposed between a respective pair of slots from the plurality of slots, the stator teeth including cooling conduits therethrough.

6. The assembly of claim 1 , wherein the in-slot portions include a first group of in-slot portions and a second group of in-slot portions, and wherein the first group of in-slot portions includes a first number of conductors and the second group of in-slot portions includes a second number of the conductors.

7. A method comprising:
obtaining preform windings including a first end, a second end, and a plurality of in-slot portions extending from the first end to the second end;
placing the preform windings into a mold, the mold including a first surface corresponding to at least a portion of an outer periphery of a molded core and a second surface corresponding to at least a portion of an interior periphery of the molded core;
injecting a curable material into the mold, the curable material including a resin and a ferromagnetic filler; and
hardening the curable material to thereby produce the molded core about the preform windings;
wherein the mold includes a first mold portion and a second mold portion, wherein the first mold portion is at least one of a housing or a portion of a stator-mounting assembly, and wherein the method further includes removing the second mold portion to thereby produce a stator assembly.

8. The method of claim 7 , wherein the ferromagnetic filler is ferrosilicon.

9. The method of claim 7 , wherein the at least one of the housing or the portion of the stator-mounting assembly is attached to the molded stator core using a mechanical interlock.

10. The method of claim 7 , further comprising disposing, prior to hardening the curable material, a cooling-conduit precursor within the mold.

11. The method of claim 10 , wherein the cooling-conduit precursor is a sacrificial material, and wherein the method further comprises removing, after hardening the curable material, the sacrificial material such that the molded core defines a cooling conduit therein.

12. The method of claim 10 , wherein the cooling-conduit precursor is a pipe including a first portion defining a first longitude and a second portion defining a second longitude, wherein the first portion is non-parallel to the second portion, and wherein the pipe is continuous between the first portion and the second portion.

13. A vehicle comprising:
an electrical power source;
a motor-generator operatively coupled to the electrical power source, the motor-generator including:
preform windings including a first end, a second end, and a plurality of in-slot portions, the plurality of in-slot portions extending from the first end to the second end; and
a molded core including a plurality of slots, each of the plurality of slots including a respective in-slot portion of the plurality of in-slot portions disposed therein, each of the plurality of slots including a wall conforming to an outer profile of the respective in-slot portion;
wherein the molded core is a molded stator core, the motor-generator further comprises at least one of a housing or a portion of a stator-mounting assembly, and wherein the at least one of the housing or the portion of the stator-mounting assembly being a portion of a mold used to form the molded stator core.

14. The vehicle of claim 13 , wherein the molded stator core is formed from a curable material including a resin and a ferromagnetic filler.

15. The vehicle of claim 14 , wherein the ferromagnetic filler is ferrosilicon.

16. The vehicle of claim 13 , wherein the at least one of the housing or the portion of the stator-mounting assembly is attached to the molded stator core using a mechanical interlock.

17. The vehicle of claim 13 , further comprising a plurality of stator teeth, each of the plurality of stator teeth being disposed between a respective pair of slots from the plurality of slots, the stator teeth including cooling conduits therethrough.

Assignees

• Gm Global Tech Operations Llc

Inventors

• Fatemi Alireza
• Coppola Anthony M
• Nehl Thomas W
• Brooks David J

Classifications

• H02K15/021 Primary

  Magnetic cores · CPC title

• B29K2995/0008

  Magnetic or paramagnetic · CPC title

• H02K1/02

  characterised by the magnetic material · CPC title

• H02K15/12

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

• B29K2065/00

  Use of polyphenylenes or polyxylylenes as moulding material · CPC title