Motor with encapsulated stator and method of making same

US 7,067,944 B2
Filed: 01/14/2005
Issued: 06/27/2006
Est. Priority Date: 12/17/1999
Status: Expired due to Term

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First Claim

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1. A motor comprising:

a) a baseplate;

b) a stator assembly comprisingi) a core having poles, andii) windings around said poles; and

c) an injection molded thermoplastic material encapsulating the windings and also locking the stator assembly to the baseplate, the baseplate and stator assembly not being in direct contact with one another but rather having a space between them filled in by the thermoplastic material;

d) wherein the baseplate is made of a thermoplastic material having a modulas of elasticity of at least 1,000,000 psi at 25°

C. and the thermoplastic material of which the baseplate is made is the same material that encapsulates the windings, and the baseplate and winding encapsulation are formed as one monolithic body.

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Abstract

A motor comprises a baseplate, a shaft supported by said baseplate, a stator assembly having windings, the stator being rigidly attached to said baseplate, and injection molded thermoplastic material encapsulating said windings. In one embodiment, the stator is coreless. In other embodiments, the stator has a core and the core is substantially encapsulated by the thermoplastic material. In preferred embodiments, the thermoplastic material secures the stator to the baseplate or forms the baseplate.

147 Citations

11 Claims

1. A motor comprising:
- a) a baseplate;
  
  b) a stator assembly comprisingi) a core having poles, andii) windings around said poles; and
  
  c) an injection molded thermoplastic material encapsulating the windings and also locking the stator assembly to the baseplate, the baseplate and stator assembly not being in direct contact with one another but rather having a space between them filled in by the thermoplastic material;
  
  d) wherein the baseplate is made of a thermoplastic material having a modulas of elasticity of at least 1,000,000 psi at 25°
  
  C. and the thermoplastic material of which the baseplate is made is the same material that encapsulates the windings, and the baseplate and winding encapsulation are formed as one monolithic body.
- View Dependent Claims (2)
- - 2. The motor of claim 1 wherein the baseplate is further made of a metal plate, the metal plate being substantially encapsulated in the thermoplastic material.

3. A motor comprising:
- a) a core having poles and windings around said poles forming a pole assembly;
  
  b) a shaft, the shaft and pole assembly not being in direct contact with one another, but rather the shaft being spaced from the pole assembly; and
  
  c) a thermoplastic material secured to the shaft and substantially encapsulating the pole assembly, the thermoplastic material joining the pole assembly to the shaft in the space between the pole assembly and the shaft, filling in the space between them such that the windings, core and shaft are rigidly fixed together.

4. A motor comprising:
- a) a baseplate;
  
  b) a stator assembly comprisingi) a core having poles, andii) windings around said poles; and
  
  c) an injection molded thermoplastic material encapsulating the windings and also locking the stator assembly to the baseplate, the baseplate and stator assembly not being in direct contact with one another but rather having a space between them filled in by the thermoplastic material wherein the thermoplastic used in the encapsulation has a vibratory dampening ratio of at least 0.05 in the range of 0–
  
  500 H_z.
- View Dependent Claims (5)
- - 5. The motor of claim 4 wherein the thermoplastic used in the encapsulation has a vibratory dampening ratio of at least 0.1 in the range of 0–
    - 500 Hz.

6. A motor comprising:
- a) a baseplate;
  
  b) a stator assembly comprisingi) a core having poles, andii) windings around said poles; and
  
  c) an injection molded thermoplastic material encapsulating the windings and also locking the stator assembly to the baseplate, the baseplate and stator assembly not being in direct contact with one another but rather having a space between them filled in by the thermoplastic material, wherein the baseplate is made of a thermoplastic material having a modulas of elasticity of at least 1,000,000 psi at 25°
  
  C. and a metal plate, the metal plate being substantially encapsulated in the thermoplastic material.

7. A motor comprising:
- a) a baseplate;
  
  b) a stator assembly comprisingi) a core having poles, andii) windings around said poles; and
  
  c) an injection molded thermoplastic material substantially encapsulating the windings and also locking the stator assembly to the baseplate, the baseplate and stator assembly not being in direct contact with one another but rather having a space between them, the thermoplastic material having a modulas of elasticity of at least 1,000,000 psi at 25°
  
  C.;
  
  d) the thermoplastic material secured to the baseplate, the thermoplastic material joining the stator assembly to the baseplate in the space between the stator assembly and the baseplate, filling in the space between them such that the windings, core and baseplate are rigidly fixed together.
- View Dependent Claims (8)
- - 8. The motor of claim 7 wherein the thermoplastic material has a modulas of elasticity of at least 2,000,000 psi at 25°
    - C.

9. A motor comprising:
- a) a core;
  
  b) at least one magnet spaced from the core; and
  
  c) a thermoplastic material substantially encapsulating the at least one magnet and filling in the space between the at least one magnet and the core such that the at least one magnet and the core are rigidly fixed together.

10. A motor comprising:
- a) at least one conductor;
  
  b) at least one magnet forming at least one pole; and
  
  c) a thermoplastic material substantially encapsulating the at least one conductor and locating and precisely positioning the at least one conductor with respect to the at least one magnet during motor operation.

11. A motor comprising:
- a) at least one conductor;
  
  b) at least one magnet forming at least one pole; and
  
  c) a thermoplastic material substantially encapsulating the at least one magnet and locating and precisely positioning the at least one magnet with respect to the at least one conductor during motor operation.

Specification

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Litigation Data

Current Assignee
Intellectual Ventures II LLC (Intellectual Ventures LLC)
Original Assignee
Encap Motor Corporation
Inventors
Lieu, Dennis K., Neal, Griffith D.
Primary Examiner(s)
Waks, Joseph

Application Number

US11/035,906
Publication Number

US 20050134124A1
Time in Patent Office

529 Days
Field of Search

None
US Class Current

310/43
CPC Class Codes

G11B 19/2009   Turntables, hubs and motors...

H02K 1/04   characterised by the materi...

H02K 1/146   consisting of a generally a...

H02K 1/18   Means for mounting or faste...

H02K 1/185   to outer stators

H02K 1/187   to inner stators

H02K 15/12   Impregnating, heating or dr...

H02K 3/38   around winding heads, equal...

H02K 5/08   Insulating casings

H02K 5/10   with arrangements for prote...

H02K 5/165   radially supporting the rot...

H02K 5/1737   radially supporting the rot...

Y10T 29/49009   Dynamoelectric machine

Y10T 29/49073   by assembling coil and core

Motor with encapsulated stator and method of making same

First Claim

9 Assignments

Litigations

5 Petitions

Accused Products

Abstract

147 Citations

11 Claims

Specification

Solutions

Use Cases

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Motor with encapsulated stator and method of making same

First Claim

9 Assignments

Subscription Required

Subscription Required

Litigations

5 Petitions

Subscription Required

Accused Products

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Abstract

147 Citations

11 Claims

Specification

Subscription Required

Solutions

Use Cases

Quick Links