Dynamoelectric machine having an encapsulated coil structure

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.

Description

technical field [0001] The present invention relates to dynamoelectric machines, and more particularly to a dynamoelectric machine having a coil structure encapsulated with thermally conductive plastic. Background technique [0002] A motor generator is a machine that produces or uses electricity. Common types of motor generators are alternators, generators and electric motors. [0003] Electric motors are used in a wide variety of applications including power tools such as drills, saws, sanding devices, yard tools such as edgers and trimmers, just to name a few examples of such tools. These devices all utilize an electric motor with an armature and a field such as a stator. The armature is usually formed from a laminated structure or core wound by multiple windings of magnet wire. The laminated structure is formed with a plurality of poles on which the magnet wire is wound. In this regard, the laminated structure may be formed with a plurality of slots into which the ma...

AI Technical Summary

Problems solved by technology

However, using larger gauge wire to wind the magnet wire will generally require a larger slot to accommodate the required number of turns of larger gauge wire, which in turn will require a larger lamination

Therefore, the armature will be larger

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