LIGHTWEIGHT AND EFFICIENT ELECTRICAL MACHINE AND METHOD OF MANUFACTURE
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United States of America Patent
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Issued Date -
Jan 3, 2013
app pub date -
Feb 28, 2011
filing date -
Apr 28, 2010
priority date (Note) -
Abandoned
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Abstract
A lightweight and efficient electrical machine element including a method of manufacture providing a stator winding for an electric machine which has a large portion of its volume containing electrically conductive strands and a small portion of its volume containing of an encapsulant material. The stator winding includes winding of a first phase (90) by shaping a portion of a bundle of conductive strands into an overlapping, multi-layer arrangement. Winding of successive phases (91, 92) occurs with further bundles of conductor strands around the preceding phases constructed into similar overlapping, multi-layer arrangements. The multiple p (90, 91, 92) are impregnated with the encapsulant material using dies (60, 80) to press the bundles into a desired form while expelling excess encapsulant prior to the curing of the encapsulant material. The encapsulated winding is removed from the dies after the encapsulant has cured. The encapsulant coating on the strands may be activated using either heat or solvent. The stator winding may be pressed into a form which has cooling channels which increase the surface area, thus enhancing convective cooling, heat dissipation, and the electrical machine's efficiency.
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