Stator assembly and manufacturing method
The apparatus of the present invention provides a stator assembly for an electric device such as a motor or a generator. The stator assembly preferably includes a generally annular stator core having a plurality of stator teeth. A stator wire is wound around each of the stator teeth to form a stator coil. An epoxy resin is applied to the stator coil and around each of the stator teeth such that the stator wire is coated and thereby electrically isolated by the epoxy resin. A coolant channel at least partially defined by the epoxy resin is positioned in close proximity to the stator coil such that the stator assembly remains cool. A corresponding method for manufacturing such a stator assembly is also provided.
1 . A stator assembly for an electronic device comprising:
a generally annular stator core including a plurality of stator teeth;
a stator wire wound around each of said plurality of stator teeth to form a stator coil; and
an epoxy resin applied to said stator coil and around each of said plurality of stator teeth such that said stator wire is coated and thereby electrically isolated by the epoxy resin.
2 . The stator assembly of claim 1 , further comprising a coolant channel positioned in close proximity to at least a portion of said stator coil.
3 . The stator assembly of claim 1 , wherein said plurality of stator teeth each include a flanged end portion adapted to retain said stator wire and said epoxy resin as it solidifies.
4 . The stator assembly of claim 1 , wherein said stator core is composed of a soft magnetic composite.
5 . The stator assembly of claim 1 , wherein said epoxy resin is configured to facilitate the transfer of heat from the stator coil through the coolant channel and out of the stator assembly.
6 . The stator assembly of claim 1 , wherein said epoxy resin is configured to prevent the introduction of contaminants into said stator coil.
7 . The stator assembly of claim 1 , wherein said epoxy resin is configured to increase the strength of the stator core.
8 . A stator assembly for an electronic device comprising:
a generally annular stator core including a plurality of stator teeth;
a stator wire wound around each of said plurality of stator teeth to form a stator coil;
an epoxy resin applied to said stator coil and around each of said plurality of stator teeth such that said stator wire is coated and thereby electrically isolated by the epoxy resin; and
a coolant channel at least partially defined by said epoxy resin, said coolant channel positioned in close proximity to at least a portion of said stator coil.
9 . The stator assembly of claim 8 , wherein said plurality of stator teeth each include a flanged end portion adapted to retain said stator wire and said epoxy resin as it solidifies.
10 . The stator assembly of claim 8 , wherein said stator core is composed of a soft magnetic composite.
11 . The stator assembly of claim 8 , wherein said epoxy resin is configured to facilitate the transfer of heat from the stator coil through the coolant channel and out of the stator assembly.
12 . The stator assembly of claim 8 , wherein said epoxy resin is configured to prevent the introduction of contaminants into said stator coil.
13 . The stator assembly of claim 8 , wherein said epoxy resin is configured to increase the strength of the stator core.
14 . A method for manufacturing a stator assembly comprising:
providing a stator tooth;
wrapping stator wire around said stator tooth to form a stator coil, said stator coil disposed about said stator tooth defining a pole;
applying epoxy resin to said stator coil such that said stator wire is coated and electrically isolated by the epoxy resin; and
assembling a plurality of poles to form a generally annular stator assembly.
15 . The method of claim 14 , wherein said providing a stator tooth includes assembling a plurality of stator tooth components to form said stator tooth.
16 . The method of claim 14 , further comprising forming a coolant channel at least partially defined by said epoxy resin.
17 . The method of claim 16 , further comprising applying a second layer of epoxy resin to said plurality of poles to maintain the attachment thereof.