Segmented Stator Coil Compaction With Multi-Jaw Pressing

The plastic injection process merges multiple functions into a single operation: the plastic simultaneously fixes the rotor magnets in the pockets and forms the radially outer contour of the rotor body. This integration eliminates the need for separate magnet fixation and contour forming processes, achieving precise roundness while managing structural complexity.

The injected plastic serves multiple functions: it acts as an adhesive to secure the rotor magnets in the pockets, forms the radially outer contour of the rotor body to achieve precise roundness, and creates a homogeneous air gap with the stator. This multi-functionality resolves the contradiction by achieving high precision without proportionally increasing complexity.

The manufacturing process merges magnet fixation and air gap formation into a single plastic injection operation. The plastic is injected to simultaneously secure the magnets and create the precise radially outer contour that ensures homogeneous air gap, eliminating the need for separate operations and reducing overall manufacturing complexity.

The injected plastic self-forms the precise radially outer contour of the rotor body during the injection process itself. The plastic material automatically takes on the required shape to create the homogeneous air gap, without requiring additional machining or adjustment operations, thereby simplifying the manufacturing process.

The invention changes the manufacturing parameters by using plastic injection with controlled temperature and pressure to form the radially outer contour. This approach achieves the required precision for high power density applications while being more feasible than traditional machining methods, as the plastic can be precisely formed during injection and then cooled to stabilize the contour.

The plastic undergoes phase transition from molten state during injection to solid state during cooling, which enables precise formation of the radially outer contour. The phase change allows the material to take on the exact required shape during injection and then lock in that shape upon cooling, achieving the precision needed for high power density without requiring post-processing.