公开(公告)号：US07096566B2

公开(公告)日：2006-08-29

申请号：US10616871

申请日：2003-07-10

申请人： Hung T. Du ,  Brandon L. Verbrugge ,  Joshua F. West ,  Michael R. Sell ,  Richard T. Walter ,  David J. Smith ,  Earl M. Ortt ,  John C. Stone ,  Howard T. White

发明人： Hung T. Du ,  Brandon L. Verbrugge ,  Joshua F. West ,  Michael R. Sell ,  Richard T. Walter ,  David J. Smith ,  Earl M. Ortt ,  John C. Stone ,  Howard T. White

IPC分类号： H02K15/00 ,  H02K15/14 ,  H02K15/16

CPC分类号： H02K1/30 ,  H01R43/10 ,  H02K1/32 ,  H02K3/12 ,  H02K3/30 ,  H02K3/345 ,  H02K3/46 ,  H02K3/48 ,  H02K3/487 ,  H02K3/50 ,  H02K3/51 ,  H02K7/04 ,  H02K9/06 ,  H02K9/20 ,  H02K9/22 ,  H02K13/006 ,  H02K13/04 ,  H02K15/0056 ,  H02K15/02 ,  H02K15/12 ,  H02K15/165 ,  Y10T29/49 ,  Y10T29/49009 ,  Y10T29/49011 ,  Y10T29/49012 ,  Y10T29/49071 ,  Y10T29/49073 ,  Y10T29/53148

摘要： 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.

摘要翻译： 缠绕在电动机的叠片中的槽中的磁铁丝全部或部分地用塑料封装。 塑料可以是导热的并且具有模制在其中的特征，其增强热传递。 塑料可能使电枢变硬，并增加其临界转速。 可以改变塑料的特性，其几何形状及其分布，以调整电枢的旋转惯性和谐振频率。 电磁线可以通过施加等静压力或塑料周围的塑料的压力被压缩到槽中。 然后可以使用较大的电磁线，其使用具有较大磁体线的电枢增加电动机的功率。 可以使用两个或三个平板模具来模制电枢周围的塑料。 平衡功能可以模制到位。 塑料可以具有基础聚合物，其是两种或更多种聚合物和各种导热填料的共混物。

公开(公告)号：US06946758B2

公开(公告)日：2005-09-20

申请号：US10616573

申请日：2003-07-10

申请人： Hung T. Du ,  Brandon L. Verbrugge ,  Joshua F. West ,  Michael R. Sell ,  Richard T. Walter ,  Earl M. Ortt ,  John C. Stone

发明人： Hung T. Du ,  Brandon L. Verbrugge ,  Joshua F. West ,  Michael R. Sell ,  Richard T. Walter ,  Earl M. Ortt ,  John C. Stone

IPC分类号： H01R39/14 ,  H01R39/32 ,  H01R39/52 ,  H02K1/04 ,  H02K1/30 ,  H02K1/32 ,  H02K3/12 ,  H02K3/30 ,  H02K3/34 ,  H02K3/46 ,  H02K3/48 ,  H02K3/487 ,  H02K3/50 ,  H02K3/51 ,  H02K5/08 ,  H02K7/04 ,  H02K9/06 ,  H02K9/20 ,  H02K9/22 ,  H02K13/00 ,  H02K13/04 ,  H02K15/12 ,  H02K15/16 ,  H02K23/00

CPC分类号： H02K3/50 ,  H01R39/14 ,  H01R39/32 ,  H02K1/30 ,  H02K1/32 ,  H02K3/12 ,  H02K3/30 ,  H02K3/345 ,  H02K3/46 ,  H02K3/48 ,  H02K3/487 ,  H02K3/51 ,  H02K5/08 ,  H02K7/04 ,  H02K9/06 ,  H02K9/20 ,  H02K9/22 ,  H02K13/006 ,  H02K13/04 ,  H02K15/12 ,  H02K15/165 ,  H02K23/00 ,  Y10T29/49009 ,  Y10T29/49011 ,  Y10T29/49012 ,  Y10T29/49071 ,  Y10T29/49075 ,  Y10T29/49078

摘要： 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.

摘要翻译： 缠绕在电动机的层压叠层中的槽中的磁铁丝全部或部分地用导热塑料封装。 当塑料模制时，具有高于导热塑料的导热率的预成形特征被嵌入模制。 预先形成的特征可以包括翅片端盖和风扇。 或者，缠绕电磁线的塑料端部线圈的端部圆顶上具有金属层，例如通过金属化。 端部圆顶可以形成为也被金属化的特征。 导热塑料在其中可以具有相变添加剂。 电磁线可以具有一层热活化的粘合剂，当塑料被模制时被激活。 层叠堆叠中的槽可以包括由导热塑料形成的槽衬。 当形成导热塑料以封装电磁线时，可以形成风扇。

公开(公告)号：US07215048B2

公开(公告)日：2007-05-08

申请号：US11201083

申请日：2005-08-10

申请人： Hung T. Du ,  Richard T. Walter ,  Michael R. Sell ,  Joshua F. West

发明人： Hung T. Du ,  Richard T. Walter ,  Michael R. Sell ,  Joshua F. West

IPC分类号： H02K1/04

CPC分类号： H02K3/50 ,  H01R39/14 ,  H01R39/32 ,  H02K1/30 ,  H02K1/32 ,  H02K3/12 ,  H02K3/30 ,  H02K3/345 ,  H02K3/46 ,  H02K3/48 ,  H02K3/487 ,  H02K3/51 ,  H02K5/08 ,  H02K7/04 ,  H02K9/06 ,  H02K9/20 ,  H02K9/22 ,  H02K13/006 ,  H02K13/04 ,  H02K15/12 ,  H02K15/165 ,  H02K23/00 ,  Y10T29/49009 ,  Y10T29/49011 ,  Y10T29/49012 ,  Y10T29/49071 ,  Y10T29/49075 ,  Y10T29/49078

摘要： An electric motor has an armature and a stators. The armature has a lamination stack having slots therein. An internal shaft extends coaxially through the lamination stack. A plurality of magnet wires are wound in the slots of the lamination stack. A commutator is disposed on the armature shaft to which ends of the magnet wires are electrically coupled. The internal is shaft coupled to an external pinion and bearing journal by an insulated coupling. The magnet wires are at least partially encased in thermally conductive plastic. 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. A power tool has the electric motor.

摘要翻译： 电动机具有电枢和定子。 电枢具有其中具有槽的叠片。 内轴同轴地延伸穿过叠片。 多个电磁线缠绕在层压叠层的槽中。 换向器设置在电枢轴上，电磁线的端部电耦合到该电枢轴上。 内部通过绝缘耦合轴联接到外部小齿轮和轴承轴颈。 磁线至少部分地被包裹在导热塑料中。 电磁线可以具有一层热活化的粘合剂，当塑料被模制时被激活。 层叠堆叠中的槽可以包括由导热塑料形成的槽衬。 当形成导热塑料以封装电磁线时，可以形成风扇。 电动工具具有电动马达。

公开(公告)号：US07464455B2

公开(公告)日：2008-12-16

申请号：US11201073

申请日：2005-08-10

申请人： Hung T. Du ,  Richard T. Walter ,  Michael R. Sell ,  Joshua F. West

发明人： Hung T. Du ,  Richard T. Walter ,  Michael R. Sell ,  Joshua F. West

IPC分类号： H02R15/00 ,  H02R1/04

CPC分类号： H02K3/50 ,  H01R39/14 ,  H01R39/32 ,  H02K1/30 ,  H02K1/32 ,  H02K3/12 ,  H02K3/30 ,  H02K3/345 ,  H02K3/46 ,  H02K3/48 ,  H02K3/487 ,  H02K3/51 ,  H02K5/08 ,  H02K7/04 ,  H02K9/06 ,  H02K9/20 ,  H02K9/22 ,  H02K13/006 ,  H02K13/04 ,  H02K15/12 ,  H02K15/165 ,  H02K23/00 ,  Y10T29/49009 ,  Y10T29/49011 ,  Y10T29/49012 ,  Y10T29/49071 ,  Y10T29/49075 ,  Y10T29/49078

摘要： A method for forming an armature for an electric motor includes securing a lamination stack having slots therein on an armature shaft. A commutator is secured on one end of the armature shaft. Magnet wires are wound in the slots in the lamination stack and ends of the magnet wires are secured to the commutator. Plastic is molded around the lamination stack, commutator and magnet wires. Excess plastic is machined off. 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.

摘要翻译： 一种用于形成用于电动机的电枢的方法包括将其中具有槽的叠片叠片固定在电枢轴上。 换向器固定在电枢轴的一端。 磁体线卷绕在层压叠层中的槽中，并且电磁线的端部固定到换向器。 塑料围绕叠片堆叠，换向器和电磁线模制。 加工过多的塑料。 电磁线可以具有一层热活化的粘合剂，当塑料被模制时被激活。 层叠堆叠中的槽可以包括由导热塑料形成的槽衬。 当形成导热塑料以封装电磁线时，可以形成风扇。

公开(公告)号：US07685697B2

公开(公告)日：2010-03-30

申请号：US11491455

申请日：2006-07-21

申请人： Hung T. Du ,  Joshua F. West ,  Richard T. Walter

发明人： Hung T. Du ,  Joshua F. West ,  Richard T. Walter

IPC分类号： H01R43/06 ,  H01R43/10

CPC分类号： H02K1/30 ,  H01R43/10 ,  H02K1/32 ,  H02K3/12 ,  H02K3/30 ,  H02K3/345 ,  H02K3/46 ,  H02K3/48 ,  H02K3/487 ,  H02K3/50 ,  H02K3/51 ,  H02K7/04 ,  H02K9/06 ,  H02K9/20 ,  H02K9/22 ,  H02K13/006 ,  H02K13/04 ,  H02K15/0056 ,  H02K15/02 ,  H02K15/12 ,  H02K15/165 ,  Y10T29/49 ,  Y10T29/49009 ,  Y10T29/49011 ,  Y10T29/49012 ,  Y10T29/49071 ,  Y10T29/49073 ,  Y10T29/53148

摘要： A method of manufacturing a power tool includes forming an armature by placing an electrically insulative sleeve on an armature shaft, securing a lamination stack having slots therein on the armature shaft with the insulative sleeve disposed therebetween, securing a commutator on one end of the armature shaft with the insulative sleeve disposed therebetween, winding magnet wires in the slots in the lamination stack and securing ends of the magnet wires to the commutator, and molding thermally conductive plastic to at least partially encase the magnet wires in plastic. The armature is then disposed in a stator to form an electric motor and the electric motor is disposed in a power tool. In an aspect, electrically insulative plastic is molded in the slots of the lamination stack to form slot liners and around the ends of the lamination stack to form end spiders.In an aspect, the method includes disposing an electrically insulative seal around the insulative sleeve and abutting the commutator to seal any gap between an end of the insulative sleeve and the commutator.

摘要翻译： 制造动力工具的方法包括：通过将电绝缘套管放置在电枢轴上来形成电枢，将其中具有狭槽的叠片叠片固定在电枢轴上，其中绝缘套筒位于电枢轴之间，将换向器固定在电枢轴的一端 其中绝缘套管设置在其间，将电磁线缠绕在叠片堆叠中的狭槽中，并将电磁线的固定端固定到换向器，并且模制导热塑料以至少部分地将电线缠绕在塑料中。 然后将电枢设置在定子中以形成电动机，并且电动机设置在电动工具中。 在一个方面，电绝缘塑料被模制在层压叠层的槽中以形成槽衬套并且围绕层压叠层的端部形成末端蜘蛛。

公开(公告)号：US07591063B2

公开(公告)日：2009-09-22

申请号：US11483322

申请日：2006-07-07

申请人： Joshua F. West

发明人： Joshua F. West

IPC分类号： H01R43/06 ,  H01R43/10

CPC分类号： H02K1/30 ,  H01R43/10 ,  H02K1/32 ,  H02K3/12 ,  H02K3/30 ,  H02K3/345 ,  H02K3/46 ,  H02K3/48 ,  H02K3/487 ,  H02K3/50 ,  H02K3/51 ,  H02K7/04 ,  H02K9/06 ,  H02K9/20 ,  H02K9/22 ,  H02K13/006 ,  H02K13/04 ,  H02K15/0056 ,  H02K15/02 ,  H02K15/12 ,  H02K15/165 ,  Y10T29/49 ,  Y10T29/49009 ,  Y10T29/49011 ,  Y10T29/49012 ,  Y10T29/49071 ,  Y10T29/49073 ,  Y10T29/53148

摘要： A method of making an armature includes placing a commutator and a lamination stack on an armature stack. Coil windings wound in slots in the lamination stack, the commutator and armature shaft are at least partially encapsulated in a first plastic. The commutator has a commutator ring divided into a plurality of segments with slots between the segments that are filled with a second plastic when the commutator is made by molding a core of the second plastic in the commutator ring before the commutator ring is mounted on the armature shaft. The mold used to mold the first plastic includes projections that extend between the tangs of the commutator and against notches at axial ends of the slots of the commutator. The notches filled with the second plastic and the projections of the mold prevent plastic flash from getting into the slots of the commutator ring.

摘要翻译： 制造电枢的方法包括将换向器和叠片堆叠放置在电枢堆叠上。 卷绕在叠片堆叠中的槽中的线圈绕组，换向器和电枢轴至少部分地封装在第一塑料中。 换向器具有分成多个段的换向器环，当换向器通过在换向器环安装在电枢上之前通过模制换向器环中的第二塑料的芯而制成时，在段之间具有填充有第二塑料的槽 轴。 用于模制第一塑料的模具包括在换向器的脚之间延伸并且在换向器的槽的轴向端部处的凹口之间延伸的突起。 填充有第二塑料的凹口和模具的突起防止塑料闪光进入换向器环的槽中。