Lubricant supported electric motor with electrical conductors functioning as an outer raceway

Patent metadata

Field	Value
Publication number	US-11652379-B2
Application number	US-202117341673-A
Country	US
Kind code	B2
Filing date	Jun 8, 2021
Priority date	Jun 8, 2020
Publication date	May 16, 2023
Grant date	May 16, 2023

Abstract

An electric motor comprises a stator presenting a first surface. A rotor is rotatable relative to the stator. The rotor presents a rotor raceway disposed in spaced relationship with the first surface of the stator. The first surface of the stator defines a plurality of slots in spaced relationship with one another to define a plurality of spaced teeth between the slots. At least one electrical conductor is disposed in each of the slots and configured to selectively create a moving magnetic field for acting upon the rotor for providing rotational movement of the rotor. A portion of the at least one electrical conductor extends substantially into radial alignment with, or past the first surface of the stator to at least partially define a stator raceway of the stator for engaging the rotor raceway of the rotor during relative radial movement between the rotor and the stator.

First claim

What is claimed is:

1. An electric motor comprising:
an annular stator extending about an axis and presenting a first radial surface;
a rotor extending about the axis and rotatable relative to the stator and presenting a second radial surface defining a rotor raceway disposed in spaced relationship with the first radial surface of the stator to define a gap therebetween for containing a lubricant;
the first radial surface of the stator defining a plurality of slots in spaced relationship with one another to define a plurality of spaced teeth between the slots;
at least one electrical conductor disposed in each of the slots and configured to selectively create a moving magnetic field for acting upon the rotor for providing rotational movement of the rotor in response to a current being applied to the at least one electrical conductor; and
a portion of the at least one electrical conductor in each of the slots extending substantially into radial alignment with, or past the first radial surface of the stator to at least partially define a stator raceway of the stator for engaging the rotor raceway of the rotor during relative movement between the rotor and the stator to function as a bearing while also creating the moving magnetic field;
wherein the at least one electrical conductor in each of the slots includes a plurality of electrical conductors in each of the slots, and wherein the plurality of electrical conductors in each of the slots includes at least a first electrical conductor radially stacked over a second electrical conductor, and wherein the first electrical conductor is made of a harder and less conductive material than the second electrical conductor;
wherein the first electrical conductor is comprised of one of a copper iron and copper zinc material, and wherein the second electrical conductor is comprised of one of an oxygen carrying copper and an oxygen-free high conductivity copper.

2. The electric motor as set forth in claim 1 , wherein the first and second electrical conductors in each of the slots are fitted in the slot using at least one of an interference press fit, thermal shrink fit, and a displacement/deformation rolling process in order to provide a tight fit of the first and second electrical conductors in the slot.

3. The electric motor as set forth in claim 1 , wherein each of the first and second electrical conductors of each of the slots defines at least one substantially planar surface, and wherein the substantially planar surfaces of the first and second layers of electrical conductors overlie and engage one another in the slot in order to provide mechanical stiffness and to minimize insulation between the first and second layers of electrical conductors.

4. The electric motor as set forth in claim 1 , wherein at least one of the electrical conductors in each of the slots includes an axially extending conductive bar.

5. The electric motor as set forth in claim 1 wherein at least one of the electrical conductors in each of the slots includes a plurality of windings.

6. The electric motor as set forth in claim 1 , wherein at least one of the electrical conductors in each of the slots extends radially inwardly past the first radial surface of the stator.

7. The electric motor as set forth in claim 1 , wherein at least one of the electrical conductors in each of the slots extends into radial alignment with the first surface of the stator such that the stator raceway is defined by circumferentially alternating segments of the electrical conductors and the first surface of the stator.

8. The electric motor as set forth in claim 1 , wherein the stator raceway presents a substantially smooth surface in the circumferential direction.

9. The electric motor as set forth in claim 8 , wherein a polymer coating extends over at least one of the electrical conductors in each of the slots and the first surface of the stator to define the substantially smooth surface of the outer raceway.

10. The electric motor as set forth in claim 1 , wherein the stator defines at least one passageway in fluid communication with the gap for passing a lubricant into the gap.

11. The electric motor as set forth in claim 1 , wherein a bearing sleeve is not located radially in the gap between the stator and the rotor.

12. The electric motor as set forth in claim 1 , wherein the plurality of electrical conductors in each of the slots further includes a third electrical conductor radially beneath the second electrical conductor, and wherein the first electrical conductor is made of a harder and less conductive material than the third electrical conductor.

13. An electric motor comprising:
an annular stator extending about an axis and presenting a first radial surface;
a rotor extending about the axis and rotatable relative to the stator and presenting a second radial surface defining a rotor raceway disposed in spaced relationship with the first radial surface of the stator to define a gap therebetween for containing a lubricant;
the first radial surface of the stator defining a plurality of slots in spaced relationship with one another to define a plurality of spaced teeth between the slots;
at least one electrical conductor disposed in each of the slots and configured to selectively create a moving magnetic field for acting upon the rotor for providing rotational movement of the rotor in response to a current being applied to the at least one electrical conductor; and
a portion of the at least one electrical conductor in each of the slots extending substantially into radial alignment with, or past the first radial surface of the stator to at least partially define a stator raceway of the stator for engaging the rotor raceway of the rotor during relative movement between the rotor and the stator to function as a bearing while also creating the moving magnetic field;
wherein the at least one electrical conductor in each of the slots includes a plurality of electrical conductors in each of the slots, and wherein the plurality of electrical conductors in each of the slots includes at least a first electrical conductor radially stacked over a second electrical conductor, and wherein the first electrical conductor is made of a harder and less conductive material than the second electrical conductor;
wherein the plurality of electrical conductors in each of the slots further includes a third electrical conductor radially beneath the second electrical conductor, and wherein the first electrical conductor is made of a harder and less conductive material than the third electrical conductor.

14. The electric motor as set forth in claim 13 , wherein the stator defines at least one passageway in fluid communication with the gap for passing a lubricant into the gap.

15. The electric motor as set forth in claim 13 , wherein each of the first and second electrical conductors of each of the slots defines at least one substantially planar surface, and wherein the substantially planar surfaces of the first and second layers of electrical conductors overlie and engage one another in the slot in order to provide mechanical stiffness and to minimize insulation between the first and second layers of electrical conductors.

16. The electric motor as set forth in claim 13 , wherein at least one of the electrical conductors in each of the slots extends radially inwardly past the first radial surface of the stator.

17. The electric motor as set forth in claim 13 , wherein at least one of the electrical conductors in each of the slots extends into radial alignment with the first surface of the stator such tha

Assignees

• Neapco Intellectual Property Holdings Llc

Inventors

• Remboski Donald
• Dedo Jacqueline
• Versteyhe Mark

Classifications

• H02K3/16 Primary

  for auxiliary purposes, e.g. damping or commutating · CPC title

• H02K2201/03

  Machines characterised by aspects of the air-gap between rotor and stator · CPC title

• H02K7/088 Primary

  radially supporting the rotor directly · CPC title

• H02K3/02

  Windings characterised by the conductor material · CPC title

• H02K5/128

  using air-gap sleeves or air-gap discs · CPC title