A STATOR FOR AN ELECTRIC MOTOR WITHOUT THE REQUIREMENT OF PAINT.

Abstract

A stator for an electric motor comprises a body with a first end and a second end, a first plate mounted at the first end of the body, a second plate mounted at the second end of the body, and a multitude of wires and an insulating layer extending through the first plate, the stator body, and the second plate. The first and second plates prevent relative movement between individual wires of the multitude of wires and the stator body.

Description

AREA

[0001] The present disclosure relates to stators for electric motors. More particularly, the present disclosure relates to eliminating paint dripping during stator manufacturing. GENERAL STATE OF THE ART

[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

[0003] Electric propulsion in vehicles provides an alternative to internal combustion engines. Electric propulsion systems use electric motors to propel the vehicle. Applying paint to such motors provides corrosion and contamination resistance, thereby increasing the service life of the electric propulsion system. The paint can be applied using a machine designed to apply the paint to the various components of the motors. However, in some situations, the paint does not fill a gap between the electric motor stator and insulating paper, and between the insulating paper and conductive wires extending through the stator.

[0004] The present disclosure addresses challenges related to paint application on electric motors. SUMMARY

[0005] This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.

[0006] In one form of the present disclosure, a stator for an electric motor includes a body having a first end and a second end, a first plate mounted to the first end of the body, a second plate mounted to the second end of the body, and a plurality of wires and an insulating layer extending through the first plate, the stator body, and the second plate. The first plate and the second plate prevent relative movement between individual wires of the plurality of wires and the stator body.

[0007] In variations of this stator, which may be implemented individually or in any combination: the first plate and the second plate are made of a plastic material; the plastic material is a polyamide imide, a polyphenylene sulfide, or a polyphenylene oxide; the first plate and the second plate are made of a ceramic material; the first plate and the second plate are molded as a single integral piece; the first plate and the second plate are formed from two separate molded pieces; the plurality of wires comprise a copper material; and bending of the plurality of wires applies a force to the first plate and the second plate to prevent relative movement between the stator and individual wires of the plurality of wires.

[0008] In another form, a stator for an electric motor includes a body having a plurality of slots, a plurality of wires and an insulating layer extending through the body, and at least one insert extending from an outer diameter to an inner diameter of a slot of the body and through at least a portion of the plurality of wires. The at least one insert prevents relative movement between individual wires of the plurality of wires.

[0009] In variations of this form, which can be implemented individually or in any combination: the at least one insert comprises a T-shaped portion and a wedge-shaped portion; the T-shaped portion comprises an elongated segment; the elongated segment is tapered; the at least one insert is made of a plastic material; the plastic material is a polyamide pimide, a polyphenylene sulfide, or a polyphenylene oxide; the at least one insert is made of a ceramic material; and the at least one insert comprises a plurality of spaced-apart inserts.

[0010] In yet another form, a stator for an electric motor includes a body having a plurality of slots, a plurality of wires, and an insulating layer extending through the body, at least one insert extending from an outer diameter to an inner diameter of a slot of the body and through at least a portion of the plurality of wires, and at least one other insert extending from the inner diameter to a midpoint between the outer diameter and the inner diameter of the slot of the body and through the subportion of the plurality of wires. The at least one insert and the at least one other insert prevent relative movement between individual wires of the plurality of wires.

[0011] In variations of this method, which may be implemented individually or in any combination: each of the at least one insert and the at least one other insert includes a T-shaped elongated portion and a wedge-shaped portion; the T-shaped elongated portion includes a tapered segment; and the stator further includes a mechanism that locks the at least one insert and the one other insert together at the midpoint to prevent movement between individual wires of the plurality of wires.

[0012] Further areas of applicability will become apparent from the description provided herein. It is understood that the description and specific examples are for illustrative purposes only and are not intended to limit the scope of the present disclosure. DRAWINGS

[0013] In order that the disclosure may be fully understood, various forms thereof will now be described by way of example with reference to the accompanying drawings, in which: Fig. 1 is a perspective view of a stator of an electric motor according to the principles of the present disclosure; Fig. 2 illustrates the stator with two annular discs according to the principles of the present disclosure; Fig. 3A illustrates a portion of an annular disc formed from two separate layers in accordance with the principles of the present disclosure; Fig. Figure 3B illustrates the section of the annular disc used in Fig. 3A, in which the two layers are combined, in accordance with the principles of the present disclosure; Fig. Figure 4A is a cross-sectional view of the annular disc, viewed along lines 4A-4A of Fig. 3B, in accordance with the principles of the present disclosure; Fig. Figure 4B is a cross-sectional view of the annular disc taken along plane 4B-4B of Fig. 4A in accordance with the principles of the present disclosure; Fig. Figure 4C is a cross-sectional view of the annular disc along the plane 4C-4C of Fig. 4A in accordance with the principles of the present disclosure; Fig. 5A illustrates another portion of an annular disc formed from two separate layers in accordance with the principles of the present disclosure; Fig. Figure 5B illustrates the section of the annular disc used in Fig. 5A, in which the two layers are combined, in accordance with the principles of the present disclosure; Fig. Figure 6A is a cross-sectional view of the annular disc, viewed along lines 6A-6A of Fig. 5B, in accordance with the principles of the present disclosure; Fig. Figure 6B is a cross-sectional view of the annular disc taken along plane 6B-6B of Fig. 6A in accordance with the principles of the present disclosure; Fig. Figure 6C is a cross-sectional view of the annular disc taken along plane 6C-6C of Fig. 6A in accordance with the principles of the present disclosure; Fig. 7 illustrates a washer that prevents relative movement of individual wires in a stator, in accordance with the principles of the present disclosure; Fig. 8A is a perspective view of a wedge that prevents relative movement of individual wires in a stator, according to the principles of the present disclosure; Fig. Figure 8B is a cross-sectional view of the wedge taken along lines 8B-8B of Fig. 8A, in accordance with the principles of the present disclosure; Fig. Figure 8C is a cross-sectional view of the wedge taken along lines 8C-8C of Fig. 8A, in accordance with the principles of the present disclosure; Fig. Figure 8D is a cross-sectional view of the wedge taken along lines 8D-8D of Fig. 8A, in accordance with the principles of the present disclosure; Fig. 9A illustrates the wedge positioned in a plurality of wires of a stator in accordance with the principles of the present disclosure; and Fig. 9B illustrates two wedges positioned in a plurality of wires of a stator in accordance with the principles of the present disclosure.

[0014] The drawings described in this document are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way. DETAILED DESCRIPTION

[0015] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that corresponding reference characters indicate like or corresponding parts and features throughout the drawings.

[0016] With reference to Fig. 1 and Fig. 2, an electric motor 10 includes a stator 12 and a plurality of wires 14. The electric motor 10 is a component of an electric drive system for a motor vehicle, i.e., an "electric vehicle." The electric motor 10 propel the motor vehicle by rotating one or more wheels of the motor vehicle. In one example, the electric motor 10 is a sole propulsion system for the vehicle, e.g., in an all-electric vehicle. Alternatively, the electric motor 10 may be part of a hybrid propulsion system that includes an internal combustion engine, e.g., in a hybrid-electric vehicle.

[0017] The electric motor 10 includes the stator 12. The stator 12 is a stationary component of the electric motor 10 that provides a magnetic field through which a rotor rotates. The stator 12 maintains the orientation of the magnetic field to rotate the rotor. The stator 12 includes a plurality of laminations 18, i.e., sheets of material fused together. Each lamination 18 is an annular sheet of metal having a continuous outer edge 20 defining an outer diameter and a plurality of fingers 22 extending toward a center point of the annular sheet. Distal ends 24 of the fingers 22 define an inner diameter of the lamination 18. Each pair of adjacent fingers 22 of one of the laminations 18 defines a slot 26 therebetween. The slots 26 extend radially from the inner diameter to an intermediate diameter. The laminations 18 are secured to the outer diameter, for example, byfused by a weld, and the laminated bodies 18 are exposed at the intermediate diameter and the inner diameter. The stator 12 includes a first laminated body 40 at a first end 42 of the stator 12 and a final laminated body at a second end 44. The laminated bodies 18 have outer surfaces 48 that contact outer surfaces of adjacent laminated bodies 18.

[0018] The wires 14 are made of an electrically conductive material, e.g., copper. The wires 14 provide electricity to generate the magnetic field that drives the rotor. The wires 14 are arranged in the slots 26 and extend along the stator 12. The wires 14 are arranged from the intermediate diameter to the inner diameter in the slots 26 defined by the fingers 22 of the laminated bodies 18.

[0019] A plate, such as a washer 46, is disposed at a first end 42 and a second end 44. The washer 46 is bolted to the stator 12 by a set of nuts 50 and a set of rods 52. The washer 46 is mirrored along a center plane 48 of the stator 12. As shown in Fig. 4B and Fig. As shown in Figure 6B, an insulating layer 60 is positioned in each slot 26 between the wires 14 and the stator 12. The insulating layer 60 reduces or prevents electrical conduction between the wires 14 and the stator 12. The insulating layer 60 is, for example, a paper layer that is electrically insulating. Each of the annular discs is formed from a ceramic or plastic material. For example, but not limited to, the plastic material can be polyamide pimide, polyphenylene sulfide, or polyphenylene sulfide.

[0020] In one form, a portion of an annular disc 46 is designated 46a in Fig. 3A and Fig. 3B. The portion of the washer 46a surrounds a single slot 26 of the stator 12 and is formed from two layers 54 and 56. The layer 54 is disposed adjacent to the stator 12, and the layer 56 includes a set of slots 58 defined by a set of plates 59 that guide a portion of the plurality of wires through the layer 54 into the stator 12. The layer 54 may, in some forms, be formed from paper. The slots 58 separate the plurality of wires 14 and prevent relative movement between the wires 14. Instead of being formed from two separate layers, the washer 46a may be formed as a single, integrated piece.

[0021] With further reference to Fig. Figure 4A is a cross-sectional view of the annular disc 46a, viewed along lines 4A-4A of Fig. 3B, attached to the stator 12. Fig. Figure 4B shows a cross-sectional view along plane 4B-4B of the inner layer 54 and Fig. 4C shows a cross-sectional view along plane 4C-4C of the outer layer 56. The inner layer 54 of the annular disk 46a provides space for the insulating layers 60 and the plurality of wires 14, while the outer layer 56 provides space only for the plurality of wires 14. Each wire of the plurality of wires 14 is sandwiched between the plates 59, which define the slots 58 and are separated from other copper wires to prevent movement between the wires 14. As shown in Fig. 2 and Fig. 4B, the plurality of wires 14 and the insulating layer 60 extend through the washer 46 at the first end 42 of the stator 12, the body of the stator 12, and the washer 46 at the second end 44 of the stator 12.

[0022] In another form, a portion of the annular disc 46 is designated 46b in Fig. 5A and Fig. 5B. The portion of the washer 46b again surrounds a single slot 26 of the stator 12 and is formed from two layers 61 and 62. Layer 61 is disposed adjacent to the stator 12, and layer 62 includes a set of slots 64 defined by a set of plates 65 that guide a portion of the plurality of wires into the stator 12.

[0023] Layer 61 may, in some forms, be formed of paper. Slots 64 separate the plurality of wires 14 and prevent relative movement between the wires 14. Instead of being formed from two separate layers, annular disc 46b may be formed as a single, integrated piece.

[0024] With further reference to Fig. Figure 6A is a cross-sectional view of the annular disc 46b, viewed along lines 6A-6A of Fig. 5B, attached to the stator 12. Fig. Figure 6B shows a cross-sectional view along plane 6B-6B of the inner layer 61 and Fig. 6C shows a cross-sectional view along plane 6C-6C of the outer layer 62. The inner layer 61 of the annular disk 46b provides space for the insulating layers 60 and the plurality of wires 14, while the outer layer 62 provides space only for the plurality of wires 14. Each wire of the plurality of wires 14 is inserted between the plates 65, which define the slots 64 and are separated from the other copper wires to prevent movement between the wires 14. As shown in Fig. 2 and Fig. 6B, the plurality of wires 14 and the insulating layer 60 extend through the washer 46 at the first end 42 of the stator 12, the body of the stator 12, and the washer 46 at the second end 44 of the stator 12.

[0025] Accordingly, the present disclosure describes the use of the annular disc 46a or 46b structurally integrated as a rigid single part into the stator 12 and the plurality of wires 14, as in Fig. 7. No relative movement is permitted between individual wires of the plurality of wires 14 and between the stator 12 and the plurality of wires 14. Near the outer diameter of the stator 12 and the washer 46a or 46b, the washer 46a or 46b is secured to the stator 12 by a set of nuts 50 and a set of rods 52 ( Fig. 2). Near the inner diameter of the stator 12 and the annular disc 46a or 46b, bending of the plurality of wires 14 creates a force 62 that pushes against the outer layers 56 or 62 to hold the plurality of wires 14 against the stator 12. The plates 59 or 65 within the outer layers 56 or 62 of the annular disc 46a or 46b hold each individual wire of the plurality of wires 14 to prevent movement of the individual wires relative to the stator 12.

[0026] With reference now to Fig. 8A to 8D, an insert 100 is shown that prevents relative movement between the wires of the plurality of wires 14. The insert 100 includes a flat T-shaped portion 102 consisting of an elongated segment 104 and a top segment 106. A wedge-shaped portion 108 is attached to the elongated segment 104. As shown in Fig. 8B, the elongated segment 104 is tapered. Thus, the taper of the elongated segment 104 and the shape of the wedge-shaped portion 108 enable placement of the insert 100 through the plurality of wires 14.

[0027] In an arrangement as in Fig. 9A, the insert 100 is placed through a portion of the plurality of wires 14. That is, the insert 100 extends from an outer diameter to an inner diameter of a corresponding slot 26 of the body of the stator 12 and through a subportion of the plurality of wires 14 to prevent relative movement between individual wires of the plurality of wires 14. Multiple inserts 100 may be used in various arrangements.

[0028] In another arrangement, as in Fig. 9B, a pair of inserts 106a and 106b are utilized. One insert 106a extends from an outer diameter to a midpoint between the outer diameter and the inner diameter of the slot 26 of the body of the stator 12 and through the sub-portion of the plurality of wires 14, and another insert 106b extends from the inner diameter to the midpoint between the outer diameter and the inner diameter of the slot 26 of the body of the stator 12 and through the sub-portion of the plurality of wires 14. A mechanism locks the two inserts 106a and 106b together at the midpoint to prevent movement between individual wires of the plurality of wires 14. In various arrangements, multiple pairs of inserts 106a and 106b 100 may be utilized.

[0029] In various arrangements, the Fig.The inserts shown in Figures 8A-8D, 9A, and 9B are made of a ceramic or plastic material. The plastic material can be polyamide-imide, polyphenylene sulfide, or polyphenylene sulfide.

[0030] Among other advantages and benefits, the present disclosure describes assemblies that eliminate paint dripping from the production of electric motors. Thus, these assemblies reduce the process complexity associated with the production of electric motors.

[0031] Unless expressly stated otherwise herein, all numerical values ​​indicating mechanical / thermal properties, composition percentages, dimensions and / or tolerances, or other characteristics are to be understood as modified by the word "about" or "approximately" when describing the scope of the present disclosure. This modification is desirable for various reasons, including industrial practice, material, manufacturing and assembly tolerances, and testability.

[0032] As used in this document, the phrase "at least one of A, B, and C" should be interpreted to mean a logical (A OR B OR C) using a non-exclusive logical OR, and should not be interpreted to mean "at least one of A, at least one of B, and at least one of C."

[0033] The description of the disclosure is merely exemplary in nature, and thus variations that do not depart from the essence of the disclosure are intended to be within the scope of the disclosure. Such variations should not be considered a departure from the spirit and scope of the disclosure.

[0034] According to the present invention, there is provided a stator for an electric motor, comprising: a body having a first end and a second end; a first plate mounted to the first end of the body; a second plate mounted to the second end of the body; and a plurality of wires and an insulating layer extending through the first plate, the body of the stator, and the second plate, the first plate and the second plate preventing relative movement between individual wires of the plurality of wires and the body of the stator.

[0035] According to one embodiment, the first plate and the second plate are made of a plastic material.

[0036] According to one embodiment, the plastic material is a polyamide imide, a polyphenylene sulfide or a polyphenylene oxide.

[0037] According to one embodiment, the first plate and the second plate are made of a ceramic material.

[0038] According to one embodiment, the first plate and the second plate are formed as a single integrated piece.

[0039] According to one embodiment, the first plate and the second plate are formed from two separate molded pieces.

[0040] According to one embodiment, the plurality of wires comprises a copper material.

[0041] According to one embodiment, bending of the plurality of wires applies a force to the first plate and the second plate to prevent relative movement between the stator and individual wires of the plurality of wires.

[0042] According to the present invention, there is provided a stator for an electric motor, comprising: a body having a plurality of slots; a plurality of wires and an insulating layer extending through the body; at least one insert extending from an outer diameter to an inner diameter of a slot of the body and through at least a portion of the plurality of wires; at least one other insert extending from the inner diameter to a midpoint between the outer diameter and the inner diameter of the slot of the body and through a subportion of the plurality of wires, wherein the at least one insert and the at least one other insert prevent relative movement between individual wires of the plurality of wires.

[0043] According to one embodiment, each of the at least one insert and the at least one other insert includes a T-shaped elongated portion and a wedge-shaped portion.

[0044] According to one embodiment, the T-shaped elongate portion comprises a tapered segment.

[0045] According to one embodiment, the invention is further characterized by a mechanism that locks the at least one insert and the other insert together at the midpoint to prevent movement between individual wires of the plurality of wires.

Claims

[1] Stator for an electric motor, the stator comprising: a body having a plurality of slots; a plurality of wires and an insulating layer extending through the body; and at least one insert extending from an outer diameter to an inner diameter of a slot of the body and through at least a portion of the plurality of wires, the at least one insert preventing relative movement between individual wires of the plurality of wires. [2] The stator of claim 1, wherein the at least one insert comprises a T-shaped portion and a wedge-shaped portion. [3] Stator according to claim 1, wherein the at least one insert is made of a plastic material. [4] The stator of claim 1, wherein the at least one insert is made of a ceramic material. [5] The stator of claim 1, further comprising at least one other insert extending from the inner diameter to a midpoint between the outer diameter and the inner diameter of the slot of the body and through a subsection of the plurality of wires. [6] The stator of claim 5, wherein each of the at least one insert and the at least one other insert comprises a T-shaped portion and a wedge-shaped portion. [7] A stator according to claim 2 or 6, wherein the T-shaped portion comprises an elongated segment. [8] A stator according to claim 7, wherein the elongated segment is tapered. [9] The stator of claim 5, wherein the at least one insert and the at least one other insert are made of a plastic material. [10] Stator according to claim 3 or 9, wherein the plastic material is a polyamide imide, a polyphenylene sulfide or a polyphenylene oxide. [11] The stator of claim 5, wherein the at least one insert and the at least one other insert are made of a ceramic material. [12] The stator of claim 5, further comprising a mechanism that locks the at least one insert and the at least one other insert together at the midpoint to prevent movement between individual wires of the plurality of wires. [13] The stator of claim 5, wherein the at least one insert and the at least one other insert are formed as a single integrated piece. [14] The stator of claim 5, wherein the at least one insert and the at least one other insert are formed from two separate molded pieces. [15] The stator of claim 1, wherein the at least one insert comprises a plurality of inserts spaced apart.

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