Abstract: A stator for an electric drive, includes a stator housing configured in the form of a stack of laminations and having a stator bore. The housing is surrounded by a cooling jacket and has opposite winding end portions. Tubular insulators abut the bore-confronting inner surface of the winding end portions, whereby the tubular insulators bound respective cavities in concert with end faces of the stator housing and the cooling jacket for receiving the winding end portions, with the cavities being filled with insulating casting material.

Abstract: A magneto-generator exhibiting high electricity generation efficiency under the forced cooling effect includes a flywheel implemented substantially in a bowl-like shape, a plurality of magnets disposed on and along an inner peripheral surface of the flywheel, a generator coil disposed internally of the flywheel in opposition to the magnets (12) for generating electricity under the action of electromagnetic induction between the magnets and the generator coil, and a plurality of resin fins provided along a peripheral edge of the flywheel at an open end thereof for generating forced gas flows in a peripheral region of the flywheel upon rotation of the flywheel for cooling the generator coil.

Abstract: The invention proposes a rotary electrical machine of the type which comprises at least one member (14) on which is formed at least one electrical winding (32) consisting of at least one electrically conductive element (34), which is wound to form the winding and which is coated with at least one layer (36) of electrically insulating material, characterised in that the coated conductive element (34) is clad with a connecting layer (72) which consists of at least one first connecting material (73) that joins together adjacent portions of the coated electrically conductive element (34). The invention also proposes a method of making a member (14) for a rotary electrical machine, characterised in that a coated conductive element (34) is clad with a connecting layer (72) that consists of at least one first connecting material (73), which is heated and solidifies in such a way as to join together the adjacent portions of the conductive element (34).

Abstract: An apparatus and method of forming a resin film on a surface of a stator core including a ring-shaped yoke portion, a plurality of teeth each protruding from the yoke portion in a radial direction, and a plurality of slots formed between the teeth, including forming the resin film on a section of the stator core by molding a synthetic resin material onto a surface of the section and repeating the molding on another section of the stator core so as to form the resin film on a whole periphery of the stator core, wherein the stator core is divided into a plurality of sections with respect to an axial center thereof.

Abstract: A molded part 45 is formed of an insulating resin in such a manner that a stator 1, electronic components 15, and a circuit substrate 3 are included in its inside. A protective layer 53 for preventing breakage of electrical connection that might occur due to expansion or shrinkage of the molded part 45 is provided at least between the electronic components 15 and the molded part 45. The protective layer 53 is formed of an insulating material having shear adhesion strength smaller than that of an insulating resin of the molded part 45 that has been cured. The shear adhesion strength and the thickness of the protective layer 53 are defined so that, when the expansion or shrinkage which might cause the breakage of the electrical connection has taken place in the insulating resin of the molded part 45, separation between the electronic components 15 and the protective layer 53 can be caused.

Abstract: In order to construct a brushless electric motor comprising a housing, comprising a rotor and comprising a stator, each stator unit including pole shoes, formed as claw poles, as well as a coil positioned following the rotor in the direction of the rotor axis, by means of which the pole shoes can be magnetized, at the lowest possible cost and as simply as possible, it is proposed that the stator unit has two pole shoe elements of which a first pole shoe element has a first pole shoe carrier as well as first pole shoes formed integrally onto this carrier and of which a second pole shoe element has a second pole shoe carrier as well as the second pole shoes formed integrally onto this carrier and that a bearing support made of plastics is molded onto the second pole shoe carrier of the stator unit and is thereby secured to it.

Abstract: A rotor assembly for a brushless motor includes a core circumferentially affixed about a longitudinal surface of a shaft. A rotor magnet covers the entire outer surface of the core to seal the core within the magnet and to prevent exposure of the core to ambient conditions. The rotor magnet has a plurality of portions of alternating magnetic polarity and is formed of a plastic mixed with neodymium-iron-boron particles.

Abstract: A drive unit for fans in vehicles has a brushless DC motor and an electronic actuation system. The electronic actuation system is surrounded by a housing made of plastics that supports the DC motor. The housing has an integrally molded bearing sleeve for mounting the rotor of the DC motor, which is configured as an external rotor. The upper part of the housing is the only supporting component of the drive unit.

Abstract: The stator for an electrical machine comprises a laminated magnetic circuit 1 having a plurality of teeth delimiting longitudinally oriented slots, electrically conductive wires 2 being disposed in the slots, and winding heads 3 at the ends of the stator. An outer sheath 4 forms part of the final motor. The stator includes a composition 6 for impregnating the winding heads, of which the filler has a large particle size, and a slot-impregnating composition 8, containing a filler of smaller particle size.

Abstract: An encapsulated stator assembly includes a plurality of like laminations stacked in registration with one another. Each lamination contacts at least one adjacent lamination, but none of them are integrally connected in any way to any other lamination. A single covering layer partially encloses and maintains in registration the plurality of like laminations. At least one post with a deflectable head extends from the covering layer. A motor assembly having a rotor assembly coupled with the stator assembly partially encapsulated by a covering layer is mountable to a control circuit board by inserting the deflectable heads into an appropriate receptacle on the circuit board. The motor assembly is used to operate a fan assembly carried by a housing. The method of molding a covering layer over the plurality of laminations is also disclosed.

Abstract: A stator assembly is formed by sandwiching a circular stator core made of soft magnetic plates from the both sides with a first magnetic-pole assembly having a part mounting section and a second magnetic-pole assembly. The stator core, the first magnetic-pole assembly, and the second magnetic-pole assembly are surrounded by a synthetic resin in a manner such that a surface at which a magnetic-pole tooth of the stator core face a rotor is exposed. The part mounting section has a plurality of holes in each of which a pin (not shown) penetrates, and holes also penetrating in the stator core at positions corresponding to the outside of the circumference of the first magnetic-pole assembly. The first magnetic-pole assembly and the part mounting section, and the second magnetic-pole assembly are fitted with the synthetic resin surrounding through the plurality of through holes provided for the stator core.

Abstract: An improved synchronous electric motor incorporating a stator and large current terminal unit made into a single unit with solidified molding resin thus a separate casing is unnecessary and thus the constitution is simplified. The large current terminal unit and a magnetic pole position detector are located on opposite sides of the stator, with the former mounted on one end of the shaft of a cooperating rotor and with the other on the other end of the rotor shaft, and they are fixed in solidified molding resin to form a single body.

Abstract: A high speed spindle motor is constructed from a stator assembly including a stator having multiple conductors that create a plurality of magnetic fields when electrical current is conducted by the conductors and a body of a phase change material such as a thermoplastic substantially encapsulating the stator. A rotatable hub having a magnet connected thereto is in operable proximity to the stator. The high speed motor also includes a shaft, a bearing surrounding the shaft and one of the bearing or shaft being fixed to the stator assembly and the other of the bearing or shaft being fixed to the rotatable hub. Hard disc drives using the motor, and methods of developing and constructing the motor and hard disc drive are also disclosed.

Abstract: Electrical motor for a pump drive, with a stator and a rotor for driving a pump impeller, the stator being embedded in a plastic body and the plastic body forming a chamber together with the stator in which the rotor is received, the chamber being closed at one shaft end of the rotor and the rotor being connected at the opposite (second) shaft end to the pump impeller.

Abstract: An electric machine in accordance with the invention includes a stator core having first and second ends and having windings therein with end turns of the windings protruding from the first and second ends of the stator core. A rotor is rotatably positioned within the stator core. A thermal conductor, such as non-laminated aluminum or aluminum alloy ring, is disposed between each stator core end-turn and the housing for conducting heat from the stator core end-turns to the housing, and the cavity between each end-turn and the thermal conductor is filled with a flexible potting material to minimize gap formation caused, for example, by thermal cycling of the engine components.

Abstract: The motor apparatus includes a motor and an insulating device. The motor such as a spindle motor is driven with pulse width modulation. Then, the insulating device insulates an object to be protected, which should be protected from a noise current generated from the motor, from the motor.

Abstract: A method for forming an electric motor includes providing a stator and an armature having a lamination stack with slots therein in which magnet wires are wound. Thermally conductive plastic is molded over at least a portion of the armature to at least partially encase the magnet wires and to mold a fan. The fan is molded without any portion of the fan extending into the slots in the lamination stack of the armature to increase the volume in the slots in which the magnet wires can be wound and the magnet wires are wound in this increased volume when they are wound in the slots in the lamination stack to increase a power rating of the electric motor beyond what is normally attainable with a fan component having portions extending into the slots in the lamination stack.

Abstract: The invention provides an electric motor in which a cost is reduced by reducing a number of the parts, and an electric motor in which a freedom of placement is increased. A motor assembly has a yoke and a front bracket closing an open end of the yoke. The front bracket is formed in a closed-end cylindrical shape by an aluminum die casting, and a brush holder for holding a brush is received in an inner portion. A motor controller for controlling the motor assembly is formed as an electronic circuit having a communication portion, a control portion and a driver portion, and this electronic circuit is mounted on an inner peripheral surface of the front bracket. Further, the electronic circuit constituting the motor controller may be mounted on the brush holder.

Abstract: An over molded motor stator structure and an over molded motor prepared with the over molded stator structure includes a stator assembly including a bobbin assembly around which a coil is wound assembled to a stator core comprising a plurality of stator laminations having an internal diameter and an external diameter. The stator assembly is encapsulated by a unitizing material which forms an over molded motor stator structure including an integral unitized stator assembly and a molded main body. The stator assembly is encapsulated such that the internal diameter and the external diameter of the stator laminations is exposed-that is, not covered or encapsulated by the unitizing material.

Abstract: An electromechanical machine includes a stator fixed with respect to a housing structure and a rotor fixed with respect to a driven shaft. The stator includes a magnetically permeable core having a plurality of parallel winding slots containing conductive windings. Coilheads are located at opposite axial ends of the magnetically permeable core where the windings turn to extend down a parallel winding slot. The motor is equipped with an electrostatic shield arrangement to reduce capacitive coupling between the stator and rotor during operation. The shield arrangement comprises a grounded conductive layer separated from the conductive windings of the stator by an insulative layer of cured resin material. Preferably, the conductive layer may be formed of a conductive paint.

Abstract: An electronically commutated brushless motor including a motor housing, a bulge formed in a sidewall of the motor housing, and a capacitor assembly housed in the bulge. The capacitor assembly includes a capacitor printed circuit board (PCB) having a plurality of longitudinal edges and at least one capacitor mounted on the capacitor PCB. The bulge includes a plurality of channels located along an inside surface of a sidewall of the bulge, in which the longitudinal edges of the capacitor assembly are slideably inserted.

Abstract: The object of the present invention is to provide not only a highly reliable resin-molded stator not suffering insulation breakdown between the different phases of the stator coils even when the operation mode where the output of a rotary machine using a resin-molded stator in which a stator coil wound around a plurality of slots and a stator coil provided at the stator core end are resin-molded is to be increased from the level under a stopped status to the maximum achievable level within a short time is repeated, but also a method of manufacturing such a stator, and a rotary machine using the same.

Abstract: If the motor housing 5 is manufactured with a resin, the housing 5 becomes possible to be manufactured by injection molding, so that the housing 5 can be intended to lower the manufacturing cost by a mass production. Further, the counter measures for insulation such as covering a copper wire 7 with an insulating tape, interposing an insulator to an opening 5a of the housing installing an insulating shim between the coil 6a and the housing 5 become unnecessary. As a result, it becomes possible to expect a cost down of the spindle motor due to the reduction of the cost of the parts for insulating members and the mounting processes. And, further, since a vibration transmitted from the rotor 1 through the bearing and a vibration caused by an electric switching of the stator 6 etc. are diminished due to elastic absorbing function of the housing 5, rotation noise of the spindle motor can be reduced.

Abstract: Magnet wires wound in slots in a lamination stack of a dynamoelectric machine are encapsulated, in whole or in part, with thermally conductive plastic. Pre-formed features having a thermal conductivity higher than the thermally conductive plastic are insert molded when the plastic is molded. The pre-formed features may include a finned end cap and a fan. Alternatively, end domes of the plastic over end coils of the wound magnet wires have a metallic layer on them, such as by being metallized. The end domes can be formed with features which are also metallized. The thermally conductive plastic can have a phase change additive in it. The magnet wires can have a layer of heat activated adhesive that is activated when the plastic is molded. Slots in the lamination stack can include slot liners formed of thermally conductive plastic. A fan can be formed when the thermally conductive plastic is molded to encapsulate the magnet wires.

Abstract: A process for preparing an over molded motor stator structure comprises constructing a bobbin assembly; constructing an intermediate stator assembly including assembling the bobbin assembly to a stator core having an internal and external diameter; disposing the intermediate stator assembly into a mold fixture comprising a cover half and an ejector half that includes an inner ejector core and a moveable plate; loading a bearing carrier into the mold fixture; closing the cover half causing the moveable plate to travel within the mold; injecting a unitizing material into the mold fixture to encapsulate the intermediate stator assembly and form an over molded motor stator structure. The moveable plate travels within the mold fixture so as prevent coating of the stator laminations external diameter. A tight tolerance relationship between the inner ejector core and the stator lamination inner diameter prevents the internal diameter from being encapsulated by the unitizing material.

Abstract: Magnet wires wound in slots in a lamination stack of a dynamoelectric machine are encapsulated, in whole or in part, with plastic. The plastic may be thermally conductive and have features molded therein that enhance heat transfer. The plastic may stiffen the armature and increase its critical speed. Characteristics of the plastic, its geometry and its distribution may be varied to adjust spinning inertia and resonant frequency of the armature. The magnet wires may be compressed into the slots, by application of iso-static pressure or by the pressure of the plastic being molded around them. Larger magnet wire can then be used which increases the power of the electric motor using the armature having the larger magnet wire. A two or three plate mold may be used to mold the plastic around the armature. Balancing features can be molded in place. The plastic can have a base polymer that is a blend of two or more polymers and various thermally conductive fillings.

Abstract: A double insulated rotor (10) for an electric motor has a rotor core (14) fitted to a shaft (12) by way of an insulating sleeve (24) moulded to the shaft (12).

Abstract: A projected board portion that is a part of a printed board is positioned externally to an outer diameter position of an annular stator, and can be connected to any of a connector and a lead wire even after resin scaling is performed. In a stator structure having a printed board according to the present invention, a projected board portion of a printed board provided to an insulating cover of an annular stator extends outward beyond an outer diameter position of the annular stator, and a connector or a lead wire can be freely selected and connected to the projected board portion.

Abstract: A d.c. PM motor and corresponding generator having a stator core assembly which is formed of a pressure-shaped processed ferromagnetic particulate material. The spaced apart isotropic core components of the stator core assembly are generally disposed in parallel relationship with the motor axis or generator axis, having a flux interaction region with a flux interaction surface located adjacent the confronting magnetic surface of a rotor and being generally coextensive with the principal dimension thereof to form an air gap. Each core component includes a winding region extending generally in parallel relationship with the device axis a field winding length to a ring-shaped back iron region. The back iron region interconnects the core components in magnetic field exchange relationship. Field windings are mounted over the core components in connection with supporting bobbins.

Abstract: The micromotor serves to drive an impeller (12) rotating in a pump housing (14). The excitation winding of the micromotor is surrounded by an enveloping flux return structure (18) of ferromagnetic material divided into rings (35). The rings (35) are separated from each other by slots (25). The slots are produced by laser cutting of a continuous tube. The enveloping flux return structure has a small wall thickness of a few tenths of a millimeter. The rings (35) are mutually connected by bridges (26). The enveloping flux return structure (18) can be integrally formed with the pump housing (14) of the pump (11). The micromotor can be produced in a small format with a small diameter. It has a high flow rate at a correspondingly high rotational speed. The micromotor is particularly suitable for introducing blood pumps into the vascular system in a non-operative minimally invasive percutaneous manner.

Abstract: An electromotive device includes an outer casing, a shaft supported by the outer casing, a bobbin disposed inside the outer casing so as to be disposed around the shaft on a common axis with the shaft, and a coil embedded in an outer molding, the coil being constructed by winding a conducting wire onto the bobbin, the bobbin and the outer molding being composed of an epoxy resin, which is an electrically-insulating material resistant to permeation by sulfur compounds.

Abstract: A gas transfer machine for use as a vacuum pump, for example, has a pump rotor mounted on a rotatable shaft for transferring a gas, and a reluctance-type motor for rotating the rotatable shaft. The reluctance-type motor has a stator, a motor rotor surrounded by the stator, and a shield member isolating the stator from the motor rotor. The motor rotor is directly coupled to the rotatable shaft and has a plurality of magnetic salient poles.

Abstract: A bearing system that includes a bearing 50 supported in a flexible bearing bracket, for example for use in fractional horsepower shaded pole type electric motors. The bearing system is self aligning, the bracket being able to deflect to compensate for deviations in the radial alignment of the rotor shaft. A rotation lock restrains the bearing against rotation within the bracket. In the preferred embodiment the bracket is composed of an elastomer and the bearing is composed of a high performance plastic polymer, so that the bearing system is non-lubricating.

Abstract: A rotary electric machine such as a fan motor or the like capable of coupling a bearing holder and an insulator to each other without deteriorating accuracy of a diameter of an inner peripheral surface of the bearing holder on which bearings are held. The bearing holder and insulator are coupled to each other by a coupling structure, which is constituted by at least one recess formed on a forward end of the bearing holder and at least one projection provided on the insulator and tightly fitted in the recess. The projection and recess thus fitted together are concurrently heated at a peripheral portion thereof for deformation, resulting in being coupled to each other.

Abstract: A magnetic armature wedge is provided for replacing conventional dovetail wedges in high-powered large-size turbine generators. The magnetic armature wedges that are used for supporting the armature bars are made by molding resin, e.g., epoxy with ferromagnetic particles, wires, laminates and the like embedded therewithin. The magnetic particles, wires, laminates and the like increase the magnetic permeability of the wedges causing higher slot flux leakage and high generator subtransient reactants.

Abstract: An electric motor having an armature which includes a coating of thermally conductive plastic applied in a conventional injection molding process. The armature also includes a fan which is integrally formed from the thermally conductive plastic applied to the armature. This completely eliminates the need to apply one or more coatings of a trickle resin to the armature. It also eliminates the need to separately form and secure a fan by a suitable adhesive to the armature, which together significantly simplifies the manufacturing and cost of the armature. The plastic coating also better fills the spaces between the magnet wires, thus promoting even more efficient cooling and better holding of the magnet wires stationary relative to one another. The thermally conductive plastic coating may be mixed with other suitable materials to provide a density approximately equal to the magnet wires. This eliminates the need to balance the armature after the injection molding step.

Abstract: A portable device integrates a small dc motor. The mounting structure of the motor allows an easy installation of the motor and to lower an electric noise level substantially. An insulating first elastic member and a conductive second elastic member are disposed around outside of a motor frame. While leaf-spring type motor-terminals are conductive to feeding terminals of a device, the motor frame is shorted by the second elastic member to a grounding terminal of the device.

Abstract: An electric motor for hand power tools has a rotor shaft, a rotor provided with a metal plate pack which is rotatably supported and non rotatably connected with the rotor shaft, the metal plate pack having a plurality of grooves which are spaced from one another in a peripheral direction and provided with a coating of insulating material, a rotor winding received in the grooves provided with the groove coating, the metal plate pack having an end plate composed of insulating material and arranged at each end side of the metal plate pack, the groove coatings and the end plates together with the rotor shaft as shaft ends axially projecting from the end plates being formed as synthetic plastic parts produced by an injection molding.

Abstract: A magnetic armature wedge is provided for replacing conventional dovetail wedges in high-powered large-size turbine generators. The magnetic armature wedges that are used for supporting the armature bars are made by molding resin, e.g., epoxy with ferromagnetic particles, wires, laminates and the like embedded therewithin. The magnetic particles, wires, laminates and the like increase the magnetic permeability of the wedges causing higher slot flux leakage and high generator subtransient reactants.

Abstract: A structure material of the present invention consisting essentially of 20 parts by weight or more of a polymer mixture consisting essentially of of a thermoplastic aromatic polyester and a thermoplastic aliphatic polyester on the basis of 100 parts by weight of the structure material. The polymer mixture comprises 3 to 40 parts by weight of the aliphatic polyester on the basis of 100 parts by weight of the polymer mixture.

Abstract: A technique for securing a conduit box to a housing of an electric motor is disclosed. The technique includes forming a hollow extension from a surface of the conduit box. The conduit box is placed on a motor frame so that the hollow extension is inserted into a hole in the motor frame that passes into the hollow interior of the motor frame. The hollow extension is plastically deformed inside the motor housing to a greater width than the diameter of the hole in the motor housing so that the conduit box cannot be removed from the motor housing. A stator is placed in the motor housing and wiring is routed from the stator to the interior of the wiring box through a passageway formed by the hollow extension.

Abstract: A fluid pump, in particular for the cooling or heating circuit of a motor vehicle, has a claw pole stator and a rotor that is separated from the claw pole stator by a tube, is immersed in a fluid, and has a vane wheel. Claws (25) of the claw pole stator (21) are an integral component of the tube (11), which is part of a motor housing (2), and the number of mounting steps is thus reduced.

Abstract: In the stator of a electric rotary machine in which heat conductive insulation resin is filled at the end portions of a stator coil, the material of a stator core, the stator coil, the heat conductive insulation resin and a frame is selected such that a linear thermal expansion coefficient &agr;1 of the stator core, a linear thermal expansion coefficient &agr;2 of the stator coil, a linear thermal expansion coefficient &agr;3 of the heat conductive insulation resin being filled and a linear thermal expansion coefficient &agr;4 of the frame satisfy a relation that &agr;1<&agr;2 <&agr;4 ≦&agr;3. A cooling medium path is integrally formed within the frame made from aluminum through die casting molding.

Abstract: Encapsulation of a permanent magnet rotor is achieved by applying a glass roving material to spaces in the rotor structure, applying a veil cloth around the outer surface of the rotor, mounting a vacuum bag with vacuum ports around the outer surface of the rotor, removing vent plugs from the end walls of the rotor and screws from an inner ring of the rotor and replacing them with vacuum ports and applying a vacuum to the vacuum ports. After air has been removed from the rotor, an encapsulating resin is applied to some of the ports to introduce resin into the interior of the rotor. After curing of the resin the vacuum bag is removed and the outer surface of the rotor is machined to the desired outer dimension of the rotor.

Abstract: An armature for a rotating electrical machine and more particularly to an insulating cover for the pole teeth around which the windings are formed that has good strength against the winding without risk of damage of the insulator due to increased thickness in the highly stressed areas.

Abstract: A rotor 1 can prevent from cracking a magnet when molding the rotor and a molding die for the rotor can prevent from reducing yield of rotors. The rotor 1 formed into disk shape includes a rotor body 12 and an annular shape magnet 13. The rotor body 12 has inner and outer cover portions 18, 19 for covering respectively inner and outer surfaces 13a, 13b of the magnet 13, and first and second end cover portions 20, 21 for covering respectively one end face 13c and the other end face 13d of the magnet 13. The rotor 1 is formed by injection molding with the molding die, whose a cavity receives the magnet 13.

Abstract: An electric traction motor for a vehicle including a housing, a wound stator field located in the housing, a rotor magnetically interacting with the wound stator field, high energy magnets configured in the rotor, and low energy magnets configured in the rotor.

Abstract: A flat type vibration motor provides a weight on a round shaped upper substrate and a portion corresponding to a winding coil arranged at one side of the upper substrate to prevent the eccentric amount from being reduced due to a slim thickness of a rotor, thereby facilitating a slim size of the motor.

Abstract: The present invention is directed to a high speed spindle motor comprising a stator assembly including a stator having multiple conductors that create a plurality of magnetic fields when electrical current is conducted by the conductors and a body of a phase change material such as a thermoplastic substantially encapsulating the stator. A rotatable hub having a magnet connected thereto is in operable proximity to the stator. The high speed motor also includes a shaft, a bearing surrounding the shaft and one of the bearing or shaft being fixed to the stator assembly and the other of the bearing or shaft being fixed to the rotatable hub. Hard disc drives using the motor, and methods of developing and constructing the motor and hard disc drives are also disclosed.

Abstract: An electric rotary machine includes a stator armature which comprises: a stator ring; a plurality of discrete salient poles each including a pole tooth and a coil, disposed inside the stator ring thereby forming a magnetic circuit, and fixed by a molding resin injected inside the stator ring from an injection port of a molding die; and a plurality of barrier walls. Each of the barrier walls is disposed between the injection port of the molding die and two coil terminal pins to which the coil has its both wire terminations connected respectively.