Abstract: A slitting and scoring machine includes an upper tooling roller and a lower tooling roller that cooperate to define a tooling nip. Each tooling roller includes an alternating series of coaxially arranged annular knives, annular dies, and annular mandrels. A web of insulation is drawn through the tooling nip to simultaneously (i) cut the web into strips, (ii) score the strips in a manner that promotes the forming of the strips, and (iii) partially form the strips into modified U-shapes. Each strip includes a longitudinally extending middle segment and a pair of longitudinally extending side segments that extend away from the middle segment in a divergent manner to define a longitudinally extending channel. Longitudinally extending grooves are formed by the scoring at the junctures of the middle segment and the side segments. The scoring/grooves promote the divergent shape of the strip.

Abstract: A slitting and scoring machine includes an upper tooling roller and a lower tooling roller that cooperate to define a tooling nip. Each tooling roller includes an alternating series of coaxially arranged annular knives, annular dies, and annular mandrels. A web of insulation is drawn through the tooling nip to simultaneously (i) cut the web into strips, (ii) score the strips in a manner that promotes the forming of the strips, and (iii) partially form the strips into modified U-shapes. Each strip includes a longitudinally extending middle segment and a pair of longitudinally extending side segments that extend away from the middle segment in a divergent manner to define a longitudinally extending channel. Longitudinally extending grooves are formed by the scoring at the junctures of the middle segment and the side segments. The scoring/grooves promote the divergent shape of the strip.

Abstract: A bobbin insulating and electric motor stator form an adjacent wire coil is made from a bobbin assembly including a first part and a second part, both formed of a dielectric thermal vacuum formable polymer. The first part includes a first flange and first tube extending integrally from the first flange. The second part includes a second flange and a second tube extending integrally from the second flange. The first and second tubes are sized and shaped so as to be engageable together to form an endless winding surface between the first and second flanges. The first and second parts are made with thermal vacuum techniques to be very thin. The thickness of the first and second parts ranges from 2 to about 25 mils, more desirably 2 to about 15 mils, still more desirably 2 to about 10 mils, and most desirably 2 to about 7 mils.

Abstract: A bobbin insulating and electric motor stator form an adjacent wire coil is made from a bobbin assembly including a first part and a second part, both formed of a dielectric thermal vacuum formable polymer. The first part includes a first flange and first tube extending integrally from the first flange. The second part includes a second flange and a second tube extending integrally from the second flange. The first and second tubes are sized and shaped so as to be engageable together to form an endless winding surface between the first and second flanges. The first and second parts are made with thermal vacuum techniques to be very thin. The thickness of the first and second parts ranges from 2 to about 25 mils, more desirably 2 to about 15 mils, still more desirably 2 to about 10 mils, and most desirably 2 to about 7 mils.