Method for producing a stator for an electric machine

Patent metadata

Field	Value
Publication number	US-11527932-B2
Application number	US-201816769578-A
Country	US
Kind code	B2
Filing date	Nov 15, 2018
Priority date	Dec 4, 2017
Publication date	Dec 13, 2022
Grant date	Dec 13, 2022

Abstract

A method for producing a stator may include providing an annular stator body including a plurality of stator teeth arranged spaced apart from one another. The method may also include at least partially overmoulding at least two adjacent stator teeth with a first plastic mass. The method may further include arranging at least one stator winding on at least one stator tooth of the at least two stator teeth and fixing the at least one stator winding on the at least one stator tooth via at least partially overmoulding the at least one stator winding with a second plastic mass. The method may additionally include, prior to fixing the at least one stator winding, introducing a mask into an intermediate space defined between the at least two stator teeth to cover a surface portion of the stator body bounding the intermediate space radially outside.

First claim

The invention claimed is:

1. A method for producing a stator for an electric machine, comprising:
providing an annular stator body including a plurality of stator teeth for receiving a plurality of stator windings, the plurality of stator teeth arranged spaced apart from one another along a circumferential direction of the stator body and protruding from the stator body radially to an inside;
at least partially overmoulding at least two stator teeth of the plurality of stator teeth that are adjacent in the circumferential direction with a first plastic mass;
arranging at least one stator winding on at least one stator tooth of the at least two stator teeth;
fixing the at least one stator winding on the at least one stator tooth via at least partially overmoulding the at least one stator winding with a second plastic mass; and
prior to fixing the at least one stator winding on the at least one stator tooth, introducing a mask into an intermediate space defined between the at least two stator teeth to cover a surface portion of the stator body bounding the intermediate space radially outside such that the surface portion is not covered with the second plastic mass when at least partially overmoulding the at least one stator winding with the second plastic mass.

2. The method according to claim 1 , wherein introducing the mask into the intermediate space includes arranging the mask in a radially outer end portion of the intermediate space.

3. The method according to claim 2 , wherein the mask completely fills the radially outer end portion.

4. The method according to claim 1 , further comprising removing the mask from the intermediate space after at least partially overmoulding that at least one stator winding with the second plastic mass to form a hollow space that defines a coolant passage for a coolant to flow through.

5. The method according to claim 4 , further comprising overmoulding at least one of (i) the second plastic mass bounding the hollow space, (ii) the at least one stator winding fixed to the at least one stator tooth, and (iii) the surface portion of the stator body, with a third plastic mass.

6. The method according to claim 5 , wherein overmoulding with the third plastic mass is carried out after removing the mask.

7. The method according to claim 6 , wherein the coolant passage is exclusively bounded by the third plastic mass.

8. The method according to claim 5 , wherein, following overmoulding with the third plastic mass, the hollow space is not directly bounded at any point by at least one of the at least one stator winding and the stator body.

9. The method according to claim 1 , wherein:
the at least two stator teeth include at least two extensions, the at least two stator teeth each including, on a radially inner end portion facing away from the stator body, at least one extension of the at least two extensions protruding therefrom in the circumferential direction, the at least two extensions disposed opposite one another in the circumferential direction, the at least two extensions forming a passage slot and partially bounding the intermediate space radially inside; and
the method further comprises, prior to at least partially overmoulding the at least two stator teeth with the first plastic mass, introducing a second mask into at least one of (i) the passage slot and (ii) a radially inner region of the intermediate space disposed following the passage slot.

10. The method according to claim 9 , wherein the second mask is introduced into the passage slot, the method further comprising removing the second mask from the passage slot after at least partially overmoulding the at least one stator winding with the second plastic mass to form a hollow space for forming a coolant passage later on.

11. The method according to claim 10 , further comprising overmoulding at least one of (i) the second plastic mass bounding the hollow space, (ii) the at least one stator winding fixed to the at least one stator tooth, and (iii) the surface portion of the stator body, with a third plastic mass to form the coolant passage that is fluidically separated from the intermediate space.

12. The method according to claim 11 , wherein the coolant passage is exclusively bounded by the third plastic mass.

13. The method according to claim 11 , wherein, following overmoulding with the third plastic mass the hollow space is not directly bounded at any point by at least one of the at least one stator winding and the stator body.

14. The method according to claim 9 , wherein the second mask completely fills the passage slot and protrudes radially to an outside into the intermediate space such that the second mask additionally fills a radially inner end portion of the intermediate space following the passage slot.

15. The method according to claim 9 , wherein:
the second mask, in a cross section of the stator body perpendicularly to a centre longitudinal axis of the stator body, has a T-like geometry with a vertical portion and with a horizontal portion; and
the vertical portion fills the passage slot and the horizontal portion fills the radially inner end portion of the intermediate space.

16. The method according to claim 1 , wherein the mask is structured as an insert.

17. The method according to claim 1 , further comprising overmoulding at least one outer circumferential side of the stator body with a third plastic mass.

18. The method according to claim 17 , wherein overmoulding the at least one outer circumferential side of the stator body with the third plastic mass includes overmoulding with the third plastic mass at least one of:
a plurality of axially extending extensions disposed on the at least one outer circumferential side, the plurality of axially extending extensions each having an end side from which a threaded rod for fastening a respective bearing shield protrudes from the stator body; and
a plurality of passage openings disposed on the at least one outer circumferential side for receiving a plurality of threaded rods.

19. The method according to claim 1 , wherein at least one of the first plastic mass and the second plastic mass at least one of (i) includes a thermosetting plastic and (ii) is composed of the thermosetting plastic.

20. The method according to claim 1 , wherein at least one of the first plastic mass and the second plastic mass at least one of (i) includes a thermoplastic and (ii) is composed of the thermoplastic.

21. The method according to claim 17 , wherein:
at least one of a plastic material of the first plastic mass and a plastic material of the second plastic mass at least one of (i) includes a thermosetting plastic and (ii) is composed of the thermosetting plastic; and
a plastic material of the third plastic mass at least one of (i) includes a thermoplastic and (ii) is composed of the thermoplastic.

22. The method according to claim 17 , wherein a heat conductivity of the third plastic mass is lower than at least one of (i) a heat conductivity of the first plastic mass and (ii) a heat conductivity of the second plastic mass.

23. The method according to claim 17 , wherein the first plastic mass, the second plastic mass, and the third plastic mass each have the same thermal conductivity.

24. The method according to claim 17 , wherein a coolant resistance of the third plastic mass is higher than at least one of (i) a coolant resistance of the second plastic mass and (ii) a coolant resistance of the fir

Assignees

• Mahle Int Gmbh

Inventors

• Cunningham John
• Grabherr Philip
• Webb Ian
• Male Tim
• Markie Stojan
• Graham Sentance
• Sever Peter
• Sonntag Josef
• Witcombe Jon

Classifications

• H02K5/203

  specially adapted for liquids, e.g. cooling jackets · CPC title

• H02K15/12

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

• H02K3/24 Primary

  with channels or ducts for cooling medium between the conductors · CPC title

• H02K9/19

  for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil · CPC title