Three-Dimensional-Flux Electric Motor And Method For Making Thereof

Patent metadata

Field	Value
Publication number	US-2024291360-A1
Application number	US-202418587232-A
Country	US
Kind code	A1
Filing date	Feb 26, 2024
Priority date	Feb 24, 2023
Publication date	Aug 29, 2024
Grant date	—

Abstract

A method of making a stator includes providing a yoke, wherein the yoke comprises a spray-formed yoke; providing a tooth ring, wherein the tooth ring comprises a spray-formed tooth ring; separating portions of the tooth ring to form a plurality of teeth; arranging the separated teeth in a circular pattern, wherein each separated tooth is spaced from an adjacent tooth; inserting a coil over each separated tooth, wherein the coil includes two lead wires extending from a same face of each coil; locating the yoke onto the plurality of teeth; placing a housing onto the yoke; and connecting the coils to each other at the two lead wires extending from the same face of each coil.

First claim

What is claimed is:

1 . A method of making a stator, comprising:
providing a yoke, wherein the yoke comprises a spray-formed yoke; providing a tooth ring, wherein the tooth ring comprises a spray-formed tooth ring; separating portions of the tooth ring to form a plurality of teeth; arranging the separated teeth in a circular pattern, wherein each separated tooth is spaced from an adjacent tooth; inserting a coil over each separated tooth, wherein the coil comprises two lead wires extending from a same face of each coil; locating the yoke onto the plurality of teeth; placing a housing onto the yoke; and connecting the coils to each other at the two lead wires extending from the same face of each coil.

2 . The method of claim 1 , wherein each tooth of the plurality of teeth is wrapped with an electrical insulation tape.

3 . The method of claim 2 , further comprising coating each tooth wrapped with the electrical insulation tape with epoxy.

4 . The method of claim 1 , wherein arranging the separated teeth in the circular pattern comprises arranging the separated teeth on a locating fixture plate.

5 . The method of claim 4 , wherein features on the locating fixture plate are accommodated between adjacently positioned teeth to align the separated teeth.

6 . The method of claim 1 , wherein placing the housing onto the yoke comprises orienting the yoke into the housing relative to locating features on the yoke.

7 . The method of claim 1 , wherein connecting the coils to each other at the two lead wires extending from the same face of each coil comprises connecting the coils in a wye or delta configuration and a series or parallel configuration.

8 . The method of claim 7 , wherein connecting the coils comprises routing interconnecting wires of the coils along a periphery of the yoke in a ring-shaped volume defined by an outer surface of the yoke, surfaces of the coils, and the housing.

9 . The method of claim 1 , further comprising placing a temperature sensing device between adjacently positioned coils.

10 . The method of claim 9 , wherein the temperature sensing device is a thermistor bulb.

11 . The method of claim 1 , wherein the spray-formed yoke and the spray-formed tooth ring are spray-formed in near-net shape manners.

12 . The method of claim 1 , further comprising using a magnet to create an attractive force on the yoke to force the yoke to make contact with the teeth.

13 . A method of making a stator, comprising:
providing a yoke, wherein the yoke comprises a spray-formed yoke; providing a tooth ring, wherein the tooth ring is a spray-formed tooth ring; separating portions of the tooth ring to form a plurality of teeth; arranging the separated teeth in a circular pattern, wherein each separated tooth is spaced from an adjacent tooth; inserting a coil over each separated tooth; locating the yoke onto the plurality of teeth; placing the yoke into an encapsulation mold; connecting the coils to each other; and injecting a resin into the encapsulation mold.

14 . The method of claim 13 , further comprising removing the encapsulation mold.

15 . The method of claim 13 , wherein injecting the resin into the encapsulation mold comprises injecting the resin into an inlet port at a bottom of the encapsulation mold and allowing the resin to flow between the coils and exit an outlet port at a top of the encapsulation mold.

16 . The method of claim 13 , wherein the resin is heated above a set temperature to lower viscosity of the resin to allow the resin to flow with a viscosity such that spaces between the separated teeth, the coils, and the yoke are filled.

17 . The method of claim 13 , wherein the spray-formed yoke and the spray-formed tooth ring are spray-formed in near-net shape manners.

18 . The method of claim 13 , further comprising using a magnet to create an attractive force on the yoke to force the yoke to make contact with the teeth.

19 . A method of assembling a stator/rotor assembly for a motor, the method comprising:
providing a housing having a bearing sleeve, the bearing sleeve extending radially inward in the housing; providing a stator, wherein the stator comprises,
a spray-formed stator yoke,
a plurality of teeth arranged in a spaced relationship on the stator yoke, and
a coil inserted over each of the separated teeth and connected to coils inserted over adjacent separated teeth;
mounting the stator in the housing on the bearing sleeve; mounting bearings proximate the bearing sleeve; and mounting a rotor comprising a rotor yoke and a plurality of magnets on the bearing sleeve, wherein mounting the rotor on the bearing sleeve comprises inserting the rotor into the housing using a gradual and controlled insertion such that an air gap is formed between the stator and the rotor, the air gap being substantially planar and normal to an axis of rotation of the rotor relative to the stator.

20 . The method of claim 19 , wherein the coils are connected to each other in a wye or delta configuration and a series or parallel configuration.

21 . The method of claim 19 , wherein mounting the bearings proximate the bearing sleeve comprises assembling an axial thrust bearing onto the bearing sleeve.

22 . The method of claim 19 , wherein mounting the bearings proximate the bearing sleeve comprises assembling a radial bearing onto the bearing sleeve.

23 . A stator for a three-dimensional flux electric motor, the stator comprising:
a stator yoke; a plurality of teeth arranged on the stator yoke, wherein teeth of the plurality of teeth are spaced from each other; and a coil located over each tooth, the coils over each tooth being connected to coils on adjacent teeth; wherein each tooth of the plurality of teeth includes a body portion having three sides connected along respective opposing side edges, each of the three sides having a bottom edge and a top edge adjacent to the opposing side edges, and a top portion located on the top edges; wherein the top portion of each tooth includes an overhang portion that overhangs the top edges of the body portion; and wherein each tooth of the plurality of teeth provides for at least a magnetic flux flow in axial, radial, and circumferential directions.

24 . The stator of claim 23 , wherein the overhang portion provides for at least a portion of the magnetic flux flow in the tooth in the radial and the circumferential directions.

25 . The stator of claim 23 , wherein the three opposing sides of the body portion include chamfered or rounded outside corners at the connected edges defining the three sides.

26 . The stator of claim 23 , wherein the bottom edges of the three sides each include a fillet at an inside corner formed by a respective side of the body portion and the stator yoke.

27 . The stator of claim 23 , wherein the teeth of the plurality of teeth are formed from an isotropic soft-magnetic composite material.

28 . The stator of claim 23 , wherein the stator yoke is spray-formed in a near-net shape manner.

29 . The stator of claim 23 , wherein the plurality of teeth are formed from a tooth ring spray-formed in a near-net shape manner, and wherein the spray-formed tooth ring is separated into the plurality of teeth.

30 . The stator of claim 23 , wherein the stator yoke comprises a p

Assignees

• Persimmon Tech Corporation

Inventors

• Krishnasamy Jayaraman
• Hosek Martin
• Taghavi Morteza
• Guralnick Brett
• Gupta Ankur
• Talmer Mark

Classifications

• H02K2205/03

  Machines characterised by thrust bearings · CPC title

• H02K3/522

  for generally annular cores with salient poles · CPC title

• H02K5/165

  radially supporting the rotor around a fixed spindle; radially supporting the rotor directly (H02K5/167, H02K5/173 take precedence) · CPC title

• H02K11/25

  Devices for sensing temperature, or actuated thereby · CPC title

• H02K16/02

  Machines with one stator and two {or more} rotors · CPC title