Patents by Inventor Tim Male

Tim Male has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 11984781
    Abstract: An electric machine includes a rotor rotatable about a rotational axis, by which an axial direction is defined, and a stator with stator windings, a coolant distributor space and a coolant collector space. The coolant distributor space communicates fluidically with the coolant collector space to cool the stator windings with a cooling duct. The stator includes stator teeth supporting the stator windings and protruding radially inward from a stator body of the stator. A stator groove is formed between two stator teeth which has a radially outer groove zone extending radially inward away from the stator body into a radially inner groove zone, the radially inner zone width of which is smaller than the radially outer zone width, when measured along the circumferential direction, of the radially outer groove zone. At least one stator winding is embedded, for thermal coupling, into an electrically insulating plastic arranged in the stator groove.
    Type: Grant
    Filed: June 3, 2020
    Date of Patent: May 14, 2024
    Assignee: MAHLE INTERNATIONAL GMBH
    Inventors: John Cunningham, Philip Grabherr, Ian Webb, Tim Male, Stojan Markic, Graham Sentance, Peter Sever, Josef Sonntag, Jon Witcombe
  • Patent number: 11735986
    Abstract: A method for producing a stator for an electrical machine includes providing the stator including a ring-shaped stator body, from which a plurality of stator teeth arranged spaced apart along a circumferential direction of the stator body protrude radially to the inside. A space is thereby provided between two stator teeth adjacent to one another in the circumferential direction. Second, a first injection molding of two stator teeth adjacent to one another in the circumferential direction with a plastic is performed. Third, a stator winding is arranged in the space. Fourth, a second injection molding of the stator winding arranged in the space with the plastic is performed such that an air gap and/or an air trap between the stator teeth injection molded in the second step and the stator winding after the arrangement of the stator winding in the space in the third step, is filled with the plastic.
    Type: Grant
    Filed: November 19, 2019
    Date of Patent: August 22, 2023
    Assignee: Mahle International GmbH
    Inventors: Roberto Almeida E Silva, Bernd Blankenbach, Terry Cox, Philip Grabherr, Niklas Kull, Tim Male, Peter Pisek, Peter Sever, Josef Sonntag, Martin Williams
  • Patent number: 11527932
    Abstract: A method for producing a stator may include providing an annular stator body including a plurality of stator teeth arranged spaced apart from one another. The method may also include at least partially overmoulding at least two adjacent stator teeth with a first plastic mass. The method may further include arranging at least one stator winding on at least one stator tooth of the at least two stator teeth and fixing the at least one stator winding on the at least one stator tooth via at least partially overmoulding the at least one stator winding with a second plastic mass. The method may additionally include, prior to fixing the at least one stator winding, introducing a mask into an intermediate space defined between the at least two stator teeth to cover a surface portion of the stator body bounding the intermediate space radially outside.
    Type: Grant
    Filed: November 15, 2018
    Date of Patent: December 13, 2022
    Inventors: John Cunningham, Philip Grabherr, Ian Webb, Tim Male, Stojan Markie, Sentance Graham, Peter Sever, Josef Sonntag, Jon Witcombe
  • Patent number: 11482900
    Abstract: An insulating body for an electric machine includes outer walls of a plastic, which delimit a body interior. In the body interior, at least one winding zone for receiving a stator winding and at least one passage zone for receiving a cooling passage are provided.
    Type: Grant
    Filed: November 19, 2019
    Date of Patent: October 25, 2022
    Assignee: Mahle International GmbH
    Inventors: Roberto Almeida E Silva, Bernd Blankenbach, Terry Cox, Philip Grabherr, Niklas Kull, Tim Male, Peter Pisek, Peter Sever, Josef Sonntag, Martin Williams
  • Patent number: 11451103
    Abstract: An electrical machine includes a rotor that is rotatable about a rotation axis, and includes a stator having electrically conductive stator windings. The machine includes a cooling channel through for cooling the stator windings. The stator has teeth extending arranged at a distance from one another along a circumferential direction of the rotor, the stator teeth protruding inwardly and carrying the stator windings. An interspace is formed between two stator teeth which are adjacent in the circumferential direction. An interspace is arranged in an insulation body having outer walls composed of a plastic, which delimit a body interior, in which a winding zone and a channel zone are provided. A stator winding is arranged in the at least one winding zone of the insulation body and a cooling channel for a is arranged in the at least one channel zone of the insulation body.
    Type: Grant
    Filed: November 18, 2019
    Date of Patent: September 20, 2022
    Inventors: Roberto Almeida E Silva, Bernd Blankenbach, Terry Cox, Philip Grabherr, Niklas Kull, Tim Male, Peter Pisek, Peter Sever, Josef Sonntag, Martin Williams
  • Publication number: 20220021259
    Abstract: An insulation body for an electrical machine may include a plurality of outer walls. The outer walls may be composed of a plastic. The outer walls may define a body interior having at least one winding zone configured to receive a stator winding, and at least one channel zone for receiving a cooling channel.
    Type: Application
    Filed: November 19, 2019
    Publication date: January 20, 2022
    Inventors: Roberto Almeida E Silva, Bernd Blankenbach, Terry Cox, Philip Grabherr, Niklas Kull, Tim Male, Peter Pisek, Peter Sever, Josef Sonntag, Martin Williams
  • Publication number: 20220014062
    Abstract: An electric machine may include a rotor and at least one cooling channel. The rotor may be rotatable about an axis defining an axial direction and include a stator having electrically conductive stator windings. A coolant may flow through the at least one cooling channel to the cool the stator windings. The stator may include teeth extending along the axial direction. The at least one cooling channel and the stator windings may be arranged in at least one intermediate space formed between two adjacent stator teeth. A plastic for transmitting heat from the stator windings to the at least one cooling channel may be arranged in the intermediate space.
    Type: Application
    Filed: November 15, 2019
    Publication date: January 13, 2022
    Inventors: Roberto Almeida E Silva, Bernd Blankenbach, Terry Cox, Philip Grabherr, Niklas Kull, Tim Male, Peter Pisek, Peter Sever, Josef Sonntag, Martin Williams
  • Publication number: 20200373799
    Abstract: A method for producing a stator may include providing an annular stator body including a plurality of stator teeth arranged spaced apart from one another. The method may also include at least partially overmoulding at least two adjacent stator teeth with a first plastic mass. The method may further include arranging at least one stator winding on at least one stator tooth of the at least two stator teeth and fixing the at least one stator winding on the at least one stator tooth via at least partially overmoulding the at least one stator winding with a second plastic mass. The method may additionally include, prior to fixing the at least one stator winding, introducing a mask into an intermediate space defined between the at least two stator teeth to cover a surface portion of the stator body bounding the intermediate space radially outside.
    Type: Application
    Filed: November 15, 2018
    Publication date: November 26, 2020
    Inventors: John Cunningham, Philip Grabherr, Ian Webb, Tim Male, Stojan Markic, Sentance Graham, Peter Sever, Josef Sonntag, Jon Witcombe
  • Publication number: 20200295618
    Abstract: An electrical machine includes a rotor, which can be rotated about an axis of rotation, with which an axial direction is defined, and a stator having stator windings, a coolant distribution chamber and a coolant collecting chamber arranged axially at a distance thereto, the coolant distribution chamber fluidically communicates with the coolant collecting chamber for cooling the stator windings, a cooling duct and a stator winding are embedded in an electrically insulating plastic for thermal coupling, the stator has stator teeth which extend along the axial direction, are spaced apart from each other along a circumferential direction and bear the stator windings, the electrically insulating plastic is arranged together with the cooling duct and the stator winding in an intermediate space, and the electrically insulating plastic is formed by a first plastic mass of a first plastic material and by a second plastic mass of a second plastic material.
    Type: Application
    Filed: June 3, 2020
    Publication date: September 17, 2020
    Inventors: John Cunningham, Philip Grabherr, Ian Webb, Tim Male, Stojan Markic, Graham Sentance, Peter Sever, Josef Sonntag, Jon Witcombe
  • Publication number: 20200295614
    Abstract: An electrical machine includes a rotor, which can be rotated about an axis of rotation, with which an axial direction is defined, and a stator having stator windings, a coolant distribution chamber and a coolant collecting chamber arranged axially at a distance thereto, the coolant distribution chamber fluidically communicates with the coolant collecting chamber for cooling the stator windings, a cooling duct and a stator winding are embedded in an electrically insulating plastic for thermal coupling, the stator has stator teeth which extend along the axial direction, are spaced apart from each other along a circumferential direction and bear the stator windings, the electrically insulating plastic is arranged together with the cooling duct and the stator winding in an intermediate space, and the electrically insulating plastic is formed by a first plastic mass of a first plastic material and by a second plastic mass of a second plastic material.
    Type: Application
    Filed: June 3, 2020
    Publication date: September 17, 2020
    Inventors: John Cunningham, Philip Grabherr, Ian Webb, Tim Male, Stojan Markic, Graham Sentance, Peter Sever, Josef Sonntag, Jon Witcombe
  • Publication number: 20200295617
    Abstract: An electric machine includes a rotor rotatable about a rotational axis, by which an axial direction is defined, and a stator with stator windings, a coolant distributor space and a coolant collector space. The coolant distributor space communicates fluidically with the coolant collector space to cool the stator windings with a cooling duct. The stator includes stator teeth supporting the stator windings and protruding radially inward from a stator body of the stator. A stator groove is formed between two stator teeth which has a radially outer groove zone extending radially inward away from the stator body into a radially inner groove zone, the radially inner zone width of which is smaller than the radially outer zone width, when measured along the circumferential direction, of the radially outer groove zone. At least one stator winding is embedded, for thermal coupling, into an electrically insulating plastic arranged in the stator groove.
    Type: Application
    Filed: June 3, 2020
    Publication date: September 17, 2020
    Inventors: John Cunningham, Philip Grabherr, Ian Webb, Tim Male, Stojan Markic, Graham Sentance, Peter Sever, Josef Sonntag, Jon Witcombe
  • Publication number: 20200295615
    Abstract: A method for producing a stator for an electric machine includes providing a stator with an annular stator body, from which a plurality of stator teeth protrude radially inwardly, wherein an intermediate space is formed in each case between two stator teeth that are adjacent in a circumferential direction, encapsulating two stator teeth adjacent in the circumferential direction with a first plastic mass, arranging a stator winding on a stator tooth, fixing the stator winding on the stator tooth by encapsulating said stator winding with a second plastic mass, following the encapsulation with the first plastic mass and before the fixing of the stator winding, a first mask is introduced into the intermediate space between the two stator teeth, such that the volume of the intermediate space that is filled with the first mask remains free from the second plastic mass to form a cooling duct during the encapsulation.
    Type: Application
    Filed: June 3, 2020
    Publication date: September 17, 2020
    Inventors: John Cunningham, Philip Grabherr, Ian Webb, Tim Male, Stojan Markic, Graham Sentance, Peter Sever, Josef Sonntag, Jon Witcombe
  • Publication number: 20200156296
    Abstract: A method for producing a stator for an electrical machine may first include providing a stator having a ring-shaped stator body, from which a plurality of stator teeth arranged spaced apart from one another along a circumferential direction of the stator body, for accommodating stator windings, protrude, wherein a space, in each case, may be embodied between two stator teeth adjacent in the circumferential direction. The method then may include first injection molding at least two stator teeth, which are adjacent in the circumferential direction, with a plastic, arranging at least one stator winding in the space between the at least two stator teeth, and second injection molding the stator winding with the plastic, so that at least one of an air gap and an air trap formed between the at least two stator teeth first injection molded and the stator winding is filled with the plastic.
    Type: Application
    Filed: November 17, 2019
    Publication date: May 21, 2020
    Inventors: Roberto Almeida E Silva, Bernd Blankenbach, Terry Cox, Philip Grabherr, Niklas Kull, Tim Male, Peter Pisek, Peter Sever, Josef Sonntag, Martin Williams
  • Publication number: 20200161917
    Abstract: The invention relates to an insulation body (100) for an electrical machine (1). The insulation body (100) comprises outer walls (101a, 101b, 101c, 101d) composed of a plastic (K), which delimit a body interior (104). At least one winding zone (106a, 106b) for receiving a stator winding (6) and at least one channel zone (107a, 107b) for receiving a cooling channel (10) are provided in the body interior (104).
    Type: Application
    Filed: November 18, 2019
    Publication date: May 21, 2020
    Inventors: Roberto Almeida E Silva, Bernd Blankenbach, Terry Cox, Philip Grabherr, Niklas Kull, Tim Male, Peter Pisek, Peter Sever, Josef Sonntag, Martin Williams
  • Publication number: 20200161947
    Abstract: A method for producing a stator for an electrical machine includes providing the stator including a ring-shaped stator body, from which a plurality of stator teeth arranged spaced apart along a circumferential direction of the stator body protrude radially to the inside. A space is thereby provided between two stator teeth adjacent to one another in the circumferential direction. Second, a first injection molding of two stator teeth adjacent to one another in the circumferential direction with a plastic is performed. Third, a stator winding is arranged in the space. Fourth, a second injection molding of the stator winding arranged in the space with the plastic is performed such that an air gap and/or an air trap between the stator teeth injection molded in the second step and the stator winding after the arrangement of the stator winding in the space in the third step, is filled with the plastic.
    Type: Application
    Filed: November 19, 2019
    Publication date: May 21, 2020
    Inventors: Roberto Almeida E Silva, Bernd Blankenbach, Terry Cox, Philip Grabherr, Niklas Kull, Tim Male, Peter Pisek, Peter Sever, Josef Sonntag, Martin Williams
  • Publication number: 20200161918
    Abstract: An insulating body for an electric machine includes outer walls of a plastic, which delimit a body interior. In the body interior, at least one winding zone for receiving a stator winding and at least one passage zone for receiving a cooling passage are provided.
    Type: Application
    Filed: November 19, 2019
    Publication date: May 21, 2020
    Inventors: Roberto Almeida E Silva, Bernd Blankenbach, Terry Cox, Philip Grabherr, Niklas Kull, Tim Male, Peter Pisek, Peter Sever, Josef Sonntag, Martin Williams
  • Publication number: 20200161916
    Abstract: An electrical machine may include a rotor rotatable about an axis of rotation, by way of which an axial direction of the electrical machine may be defined, a stator having electrically conductive stator windings, and at least one cooling channel through which a coolant may be flowable for cooling the stator windings. The stator may have stator teeth extending along the axial direction, arranged spaced apart from another along a circumferential direction of the rotor, and bearing the stator windings. The at least one cooling channel and at least one stator winding may be arranged in at least one intermediate space formed between two stator teeth adjacent in the circumferential direction. A plastic for transferring heat from the at least one stator winding to the at least one cooling channel may be arranged in the at least one intermediate space.
    Type: Application
    Filed: November 17, 2019
    Publication date: May 21, 2020
    Inventors: Roberto Almeida E Silva, Bernd Blankenbach, Terry Cox, Philip Grabherr, Niklas Kull, Tim Male, Peter Pisek, Peter Sever, Josef Sonntag, Martin Williams