I IIIII
`111111
`
`
`1111111111111111111111111111111111111111111111111111111111111 1111111111111111111111111111111111111111111111111111111111111
`
`US007 4 71 025B2 US0074 71 025B2
`
`c12) United States Patent (12) United States Patent
`
`Sheeran et al.
`Sheeran et al.
`
`(10) Patent No.:
`(10) Patent No.:
`(45) Date of Patent:
`(45) Date of Patent:
`
`US 7,471,025 B2
`US 7,471,025 B2
`Dec. 30, 2008
`Dec. 30, 2008
`
`
`(54) SEGMENTED STATOR WITH IMPROVED (54) SEGMENTED STATOR WITH IMPROVED
`
`HANDLING AND WINDING HANDLING AND WINDING
`CHARACTERISTICS
`CHARACTERISTICS
`
`(75)
`(75)
`
`Inventors: Kent A. Sheeran, Festus, MO (US);
`Inventors: Kent A. Sheeran, Festus, MO (US);
`
`Payman Rassoolkhani, Maryland Payman Rassoolkhani, Maryland
`
`Heights, MO (US); Paul G. Michaels, Heights, MO (US); Paul G. Michaels,
`
`St. Louis, MO (US) St. Louis, MO (US)
`
`(73) Assignee: Emerson Electric Co., St. Louis, MO
`(73) Assignee: Emerson Electric Co., St. Louis, MO
`
`(US) (US)
`
`
`
`( *) Notice: ( *) Notice:
`
`
`Subject to any disclaimer, the term of this Subject to any disclaimer, the term of this
`
`patent is extended or adjusted under 35 patent is extended or adjusted under 35
`
`U.S.C. 154(b) by 0 days. U.S.c. 154(b) by 0 days.
`
`(21) Appl. No.: 12/029,998
`(21) Appl. No.: 12/029,998
`
`(22) Filed:
`(22) Filed:
`
`
`
`Feb.12,2008 Feb. 12,2008
`
`
`
`(65) (65)
`
`
`
`Prior Publication Data Prior Publication Data
`
`
`
`US 2008/0129142 Al US 2008/0129142 Al
`
`
`
`Jun. 5,2008 Jun. 5,2008
`
`
`6,121,711 A 6,121,711 A
`
`6,127,753 A 6,127,753 A
`
`6,177,751 B1 6,177,751 Bl
`
`6,226,856 B1 6,226,856 Bl
`
`
`9/2000 Nakahara 9/2000 Nakahara
`10/2000 Yamazaki
`10/2000 Yamazaki
`
`1/2001 Suzuki 112001 Suzuki
`
`5/2001 Kazama 5/2001 Kazama
`
`
`
`(Continued) (Continued)
`
`
`
`FOREIGN PATENT DOCUMENTS FOREIGN PATENT DOCUMENTS
`
`
`
`JP JP
`
`
`
`11-089128 11-089128
`
`
`
`3/1990 3/1990
`
`
`
`(Continued) (Continued)
`
`OTHER PUBLICATIONS
`OTHER PUBLICATIONS
`
`
`International Search Report, PCT/US03/32557, dated Feb. 27,2004, International Search Report, PCT/US03/32557, dated Feb. 27, 2004,
`3 pgs.
`3 pgs.
`
`
`Primary Examiner-Dang D Le Primary Examiner-Dang D Le
`
`(74) Attorney, Agent, or Firm-Seuniger Powers LLP (74) Attorney, Agent, or Firm-Seuniger Powers LLP
`
`
`
`Related U.S. Application Data Related U.S. Application Data
`
`
`
`(57) (57)
`
`ABSTRACT
`ABSTRACT
`
`
`(60) Continuation of application No. 11/534,705, filed on (60) Continuation of application No. 111534,705, filed on
`
`Sep. 25, 2006, now Pat. No. 7,345,397, and a division Sep. 25, 2006, now Pat. No. 7,345,397, and a division
`
`of application No. 10/427,450, filed on Apr. 30, 2003, of application No.1 0/427,450, filed on Apr. 30, 2003,
`now Pat. No. 7,111,380.
`now Pat. No. 7,111,380.
`
`
`(60) Provisional application No. 60/422,676, filed on Oct. (60) Provisional application No. 60/422,676, filed on Oct.
`
`31, 2002. 31,2002.
`
`(51) (51)
`
`
`
`
`Int. Cl. Int. Cl.
`H02K 1106
`(2006.01)
`H02K 1106
`(2006.01)
`
`(52) U.S. Cl. ....................................... 310/217; 310/218 (52) U.S. Cl. ....................................... 3101217; 310/218
`
`(58) Field of Classification Search .......... 310/216-218 (58) Field of Classification Search .......... 310/216-218
`See application file for complete search history.
`See application file for complete search history.
`
`
`
`(56) (56)
`
`References Cited
`References Cited
`
`
`
`U.S. PATENT DOCUMENTS U.S. PATENT DOCUMENTS
`
`
`4,350,914 A 4,350,914 A
`
`5,592,731 A 5,592,731 A
`
`5,729,072 A 5,729,072 A
`6,081,059 A
`6,081,059 A
`
`911982 Searle
`9/1982 Searle
`111997 Huang
`111997 Huang
`311998 Hirano
`3/1998 Hirano
`6/2000 Hsu
`6/2000 Hsu
`
`
`
`30 30
`
`
`A stator assembly has discrete stacks of laminations. A plu(cid:173)A stator assembly has discrete stacks of laminations. A plu(cid:173)
`
`rality of nonmagnetic containment structures define pockets. rality of nonmagnetic containment structures define pockets.
`
`The stacks are at least partially received in the pockets and The stacks are at least partially received in the pockets and
`
`coupled to one another by the containment structure. The coupled to one another by the containment structure. The
`
`containment structures are moveable between a first configu(cid:173)containment structures are moveable between a first configu(cid:173)
`
`ration in which the stacks are separate from one another and ration in which the stacks are separate from one another and
`
`a second configuration in which yokes of adjacent stacks are a second configuration in which yokes of adjacent stacks are
`
`in physical contact with one another. In a method of making in physical contact with one another. In a method of making
`
`a stator assembly, a plurality of stator segments are positioned a stator assembly, a plurality of stator segments are positioned
`
`so each is received in one of a plurality of pockets in a so each is received in one of a plurality of pockets in a
`
`containment structure. Coils are wound around each stator containment structure. Coils are wound around each stator
`
`segment while the containment structure prevents the stator segment while the containment structure prevents the stator
`
`segment from having direct physical contact with another segment from having direct physical contact with another
`
`stator segment. The containment structure is reconfigured to stator segment. The containment structure is reconfigured to
`
`bring the wound stator segments into contact with one bring the wound stator segments into contact with one
`
`another, thereby forming a closed magnetic circuit. another, thereby forming a closed magnetic circuit.
`
`8 Claims, 9 Drawing Sheets
`8 Claims, 9 Drawing Sheets
`
`53
`53
`
`Page 1 of 17
`
`PETITIONERS' EXHIBIT 1010
`
`

`

`
`US 7,471,025 B2 US 7,471,025 B2
`
`Page 2 Page 2
`
`u.s. PATENT DOCUMENTS
`U.S. PATENT DOCUMENTS
`3/2002 Nakahara
`
`6,362,553 B1 6,362,553 Bl
`3/2002 Nakahara
`4/2002 Akita
`6,369,687 B1 6,369,687 Bl
`
`4/2002 Akita
`1212002 Ketterer
`6,487,769 B2
`12/2002 Ketterer
`6,487,769 B2
`112003 Kazama
`6,504,284 B1 6,504,284 Bl
`
`112003 Kazama
`112003 Nishiyama
`
`6,509,665 B1 6,509,665 Bl
`112003 Nishiyama
`6/2003 Hsu
`6,573,632 B2
`6/2003 Hsu
`6,573,632 B2
`7/2003 Peachee
`6,584,813 B2
`6,584,813 B2
`7/2003 Peachee
`1212003 Akita
`
`6,659,385 B2 6,659,385 B2
`12/2003 Akita
`3/2004 Williams
`
`6,700,284 B2 6,700,284 B2
`3/2004 Williams
`5/2004 Daikoku
`6,737,778 B2
`5/2004 Daikoku
`6,737,778 B2
`5/2004 Vohlgemuth
`
`6,741,005 B2 6,741,005 B2
`5/2004 Vohlgemuth
`6/2004 Harter
`6,744,166 B2
`6/2004 Harter
`6,744,166 B2
`212005 Masumoto
`6,856,064 B2
`2/2005 Masumoto
`6,856,064 B2
`5/2005 Peachee
`6,897,591 B2
`5/2005 Peachee
`6,897,591 B2
`3/2006 Peachee
`
`7,012,350 B2 7,012,350 B2
`3/2006 Peachee
`
`
`7,067,952 B2 * 7,067,952 B2 *
`
`7,084,545 B2 * 7,084,545 B2 *
`
`200110030483 A1 200110030483 Al
`
`2002/0093269 A1 200210093269 Al
`
`2002/0139606 A1 200210139606 Al
`
`2004/0051417 A1 2004/0051417 Al
`
`6/2006 Neal .......................... 310/259
`6/2006 Neal .......................... 310/259
`812006 Happel ....................... 310/218
`8/2006 Happel ....................... 310/218
`10/2001 Masumoto
`10/2001 Masumoto
`7/2002 Harter
`7/2002 Harter
`1012002 Williams
`10/2002 Williams
`312004 Yamazaki
`3/2004 Yamazaki
`
`
`
`FOREIGN PATENT DOCUMENTS FOREIGN PATENT DOCUMENTS
`
`
`JP JP
`
`7-245895 7-245895
`
`JP JP
`
`9-191588 9-191588
`
`JP JP
`
`11-341717 11-341717
`
`JP JP
`2001-025185
`2001-025185
`
`JP JP
`2002-218716
`2002-218716
`
`JP JP
`2002-305848
`2002-305848
`wo
`
`02-47240 A1 02-47240 Al
`WO
`
`* cited by examiner * cited by examiner
`
`9/1995
`9/1995
`7/1997
`7/1997
`12/1999
`12/1999
`
`1/2001 112001
`212002
`212002
`
`10/2002 10/2002
`6/2002
`6/2002
`
`Page 2 of 17
`
`

`

`u.s. Patent
`U.s. Patent
`
`Dec. 30, 20os
`Dec. 30, 2008
`
`Sheet 1 of9
`Sheet 1 o£9
`
`Vs 7,471,025 B2
`Vs 7,471,025 B2
`
`.
`C!)
`0:
`
`Page 3 of 17
`
`

`

`u.s. Patent
`U.S. Patent
`
`Dec. 30, 2008
`Dec. 30, 2008
`
`Sheet 2 of 9
`Sheet 2 of 9
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`US 7,471,025 B2
`US 7,471,025 B2
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`Dec. 30, 2008 Dec. 30, 2008
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`US 7,471,025 B2
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`53 53
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`FIG. 3B FIG.3B
`
`Page 7 of 17
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`

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`Dec. 30, 2008
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`

`

`u.s. Patent
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`Dec. 30, 2008 Dec. 30, 2008
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`

`

`US 7,471,025 B2
`US 7,471,025 B2
`
`
`1 1
`
`SEGMENTED STATOR WITH IMPROVED SEGMENTED STATOR WITH IMPROVED
`HANDLING AND WINDING
`HANDLING AND WINDING
`CHARACTERISTICS
`CHARACTERISTICS
`
`
`CROSS-REFERENCE TO RELATED CROSS-REFERENCE TO RELATED
`
`APPLICATIONS APPLICATIONS
`
`
`This application is a continuation of pending U.S. patent This application is a continuation of pending U.S. patent
`
`application Ser. No. 11/534,705, filed Sep. 25, 2006, which is application Ser. No. 111534,705, filed Sep. 25, 2006, which is
`
`a division of U.S. Pat. No. 7,111,380, filed Apr. 30, 2003, 10 a division of U.S. Pat. No. 7,111,380, filed Apr. 30, 2003, 10
`
`which claims priority from Provisional Patent Application which claims priority from Provisional Patent Application
`
`Ser. No. 60/422,676 filed Oct. 31, 2002, each of which is Ser. No. 60/422,676 filed Oct. 31, 2002, each of which is
`
`hereby incorporated by reference. hereby incorporated by reference.
`
`
`
`FIELD OF THE INVENTION FIELD OF THE INVENTION
`
`The present disclosure relates to stator assemblies for elec(cid:173)
`The present disclosure relates to stator assemblies for elec(cid:173)
`tromagnetic machines and, more particularly, to segmented
`tromagnetic machines and, more particularly, to segmented
`stator assemblies in which the stator is formed from a number
`stator assemblies in which the stator is formed from a number
`
`of discrete stator stacks or segments with each stator segment 20 of discrete stator stacks or segments with each stator segment 20
`
`comprising a yoke portion, a tooth portion and a coil winding comprising a yoke portion, a tooth portion and a coil winding
`
`wound about the tooth. wound about the tooth.
`
`BACKGROUND OF THE INVENTION
`BACKGROUND OF THE INVENTION
`
`2
`2
`
`An alternate conventional approach for forming a "seg(cid:173)An alternate conventional approach for forming a "seg(cid:173)
`
`mented stator like" machine that does not require the use of mented stator like" machine that does not require the use of
`
`hinges or puzzle locks relies upon the use of a stator assembly hinges or puzzle locks relies upon the use of a stator assembly
`
`formed from groupings of stator segments that are magneti(cid:173)formed from groupings of stator segments that are magneti(cid:173)
`
`cally coupled together by a thin, interconnecting bridge. Such cally coupled together by a thin, interconnecting bridge. Such
`a design is disclosed, for example, in Japanese Patent
`a design is disclosed, for example, in Japanese Patent
`
`B-30107085. Through the use of such a bridge, it appears B-30107085. Through the use of such a bridge, it appears
`
`possible to have a grouping of three stator teeth that are possible to have a grouping of three stator teeth that are
`
`coupled together magnetically by a bridge element but that coupled together magnetically by a bridge element but that
`
`are opened to some degree allowing greater access to the are opened to some degree allowing greater access to the
`
`stator teeth and, thus, greater slot fill. One limitation of this stator teeth and, thus, greater slot fill. One limitation of this
`
`approach is that the stator assembly will typically require approach is that the stator assembly will typically require
`
`more than three stator teeth such that construction of the more than three stator teeth such that construction of the
`15 complete stator assembly will require the use of multiple
`15 complete stator assembly will require the use of multiple
`groupings of three stator segments, which necessitates mul(cid:173)
`groupings of three stator segments, which necessitates mul(cid:173)
`
`tiple manufacturing steps of coupling the winding coils from tiple manufacturing steps of coupling the winding coils from
`
`the stator groupings together and structure for coupling the the stator groupings together and structure for coupling the
`
`multiple stator groupings to form an annular stator. Such multiple stator groupings to form an annular stator. Such
`additional manufacturing steps and structure can significantly
`additional manufacturing steps and structure can significantly
`increase the costs and manufacturing complexity associated
`increase the costs and manufacturing complexity associated
`with such stators.
`with such stators.
`The present disclosure describes several embodiments of a
`The present disclosure describes several embodiments of a
`25 stator assembly that are designed to address the described and
`25 stator assembly that are designed to address the described and
`other limiting characteristics of conventional segmented sta-
`other limiting characteristics of conventional segmented sta-
`
`tor assemblies. tor assemblies.
`
`
`While the use of distinct and separately wound stator seg(cid:173)While the use of distinct and separately wound stator seg(cid:173)
`
`ments provides some benefits, it potentially increases the ments provides some benefits, it potentially increases the
`
`complexity and costs of manufacturing operations. For complexity and costs of manufacturing operations. For
`
`example, in many segmented stators the stator segments are example, in many segmented stators the stator segments are
`
`wound individually and one or more manufacturing steps are 30 wound individually and one or more manufacturing steps are 30
`
`required to appropriately interconnect all the individual stator required to appropriately interconnect all the individual stator
`
`coils to form the phase windings. In such conventional stator coils to form the phase windings. In such conventional stator
`
`assemblies, because the distinct and separately wound stator assemblies, because the distinct and separately wound stator
`
`segments are not coupled together during the winding opera(cid:173)segments are not coupled together during the winding opera(cid:173)
`
`tion, some retention structure is required to hold the stator 35 tion, some retention structure is required to hold the stator 35
`
`segments together when they are formed into an annular segments together when they are formed into an annular
`
`stator. The requirements for the coil interconnecting step, the stator. The requirements for the coil interconnecting step, the
`
`materials and equipment required for the same, and the need materials and equipment required for the same, and the need
`
`for a secondary retention mechanism often require a signifi(cid:173)for a secondary retention mechanism often require a signifi(cid:173)
`
`cant capital investment in manufacturing equipment to manu- 40 cant capital investment in manufacturing equipment to manu - 40
`
`facture such machines and significant material cost adds to facture such machines and significant material cost adds to
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`the component costs of machines made according to such the component costs of machines made according to such
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`processes. processes.
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`In an effort to overcome some of the limitations associated In an effort to overcome some of the limitations associated
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`with stator assemblies having separately-wound stator seg(cid:173)with stator assemblies having separately-wound stator seg(cid:173)
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`ments as described above, approaches were developed ments as described above, approaches were developed
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`wherein magnetically-interconnected stator segments were wherein magnetically-interconnected stator segments were
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`physically coupled to one another prior to the winding opera(cid:173)physically coupled to one another prior to the winding opera(cid:173)
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`tion such that the coils could be formed in an interconnected tion such that the coils could be formed in an interconnected
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`manner. In known conventional approaches, the stator seg- 50 manner. In known conventional approaches, the stator seg- 50
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`ments were interconnected though the use of hinges, some(cid:173)ments were interconnected though the use of hinges, some(cid:173)
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`times referred to as puzzle lock connections, or through the times referred to as puzzle lock connections, or through the
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`use of thin interconnecting bridges of magnetically perme(cid:173)use of thin interconnecting bridges of magnetically perme(cid:173)
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`able materials. Such interconnecting structure often requires able materials. Such interconnecting structure often requires
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`relatively complex stator lamination constructions, which can 55 relatively complex stator lamination constructions, which can 55
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`increase the overall manufacturing costs for a machine utiliz(cid:173)increase the overall manufacturing costs for a machine utiliz(cid:173)
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`ing such a design. Moreover, the manufacturing steps ing such a design. Moreover, the manufacturing steps
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`required to couple the distinct stator segments together via the required to couple the distinct stator segments together via the
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`hinge or puzzle lock structure increases the cost and complex(cid:173)hinge or puzzle lock structure increases the cost and complex(cid:173)
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`ity of the manufacturing process. ity of the manufacturing process.
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`One limitation of stator assemblies using interconnecting One limitation of stator assemblies using interconnecting
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`puzzle pieces or bridges is that the stator assembly is often puzzle pieces or bridges is that the stator assembly is often
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`fairly inflexible and access to the stator teeth during the wind(cid:173)fairly inflexible and access to the stator teeth during the wind(cid:173)
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`ing operation is somewhat limited. These limitations can ing operation is somewhat limited. These limitations can
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`restrict the extent to which magnetic wires can be placed in 65 restrict the extent to which magnetic wires can be placed in 65
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`the stator to form the stator windings or, in other words, the the stator to form the stator windings or, in other words, the
`"slot fill."
`"slot fill."
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`SUMMARY OF THE INVENTION
`SUMMARY OF THE INVENTION
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`45
`45
`
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`In one aspect, the present invention is directed to a stator In one aspect, the present invention is directed to a stator
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`assembly. The assembly has a plurality of discrete stacks of assembly. The assembly has a plurality of discrete stacks of
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`laminations. Each of the stacks has a yoke and a tooth extend(cid:173)laminations. Each of the stacks has a yoke and a tooth extend(cid:173)
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`ing away from the yoke. A plurality of noumagnetic contain(cid:173)ing away from the yoke. A plurality of noumagnetic contain(cid:173)
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`ment structures define pockets. The stacks are at least par(cid:173)ment structures define pockets. The stacks are at least par(cid:173)
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`tially received in the pockets. The containment structures tially received in the pockets. The containment structures
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`couple the stacks to one another. The containment structures couple the stacks to one another. The containment structures
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`are moveable between a first configuration in which the stacks are moveable between a first configuration in which the stacks
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`are separate from one another and a second configuration in are separate from one another and a second configuration in
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`which the yokes of adjacent stacks are in physical contact which the yokes of adjacent stacks are in physical contact
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`with one another to form a magnetic circuit. with one another to form a magnetic circuit.
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`Another aspect of the invention is a method of making a Another aspect of the invention is a method of making a
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`stator assembly. The method includes positioning a plurality stator assembly. The method includes positioning a plurality
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`of stator segments so each stator segment is received in one of of stator segments so each stator segment is received in one of
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`a plurality of pockets in a containment structure. Coils are a plurality of pockets in a containment structure. Coils are
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`wound around each of the stator segments while the contain(cid:173)wound around each of the stator segments while the contain(cid:173)
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`ment structure prevents the respective stator segment from ment structure prevents the respective stator segment from
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`having direct physical contact with another stator segment. having direct physical contact with another stator segment.
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`The containment structure is reconfigured to bring the wound The containment structure is reconfigured to bring the wound
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`stator segments into contact with one another, thereby form-stator segments into contact with one another, thereby form-
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`ing a closed magnetic circuit. ing a closed magnetic circuit.
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`Still another aspect of the present invention is a method of Still another aspect of the present invention is a method of
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`making a stator assembly comprising a plurality of stator making a stator assembly comprising a plurality of stator
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`segments and windings coiled aronnd the stator segments. A segments and windings coiled aronnd the stator segments. A
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`plurality of stator segments are sandwiched between first and plurality of stator segments are sandwiched between first and
`60 second containment structures having a series of pockets 60 second containment structures having a series of pockets
`
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`connected by flexible hinges so each stator segment is connected by flexible hinges so each stator segment is
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`received in a pocket of the first containment structure and received in a pocket of the first containment structure and
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`received in a pocket of the second containment structure. received in a pocket of the second containment structure.
`Coils are wound around the stator segments. The containment
`Coils are wound around the stator segments. The containment
`structures are reconfigured to bring the wonnd stator seg(cid:173)
`structures are reconfigured to bring the wonnd stator seg(cid:173)
`ments into contact with one another, thereby forming a closed
`ments into contact with one another, thereby forming a closed
`magnetic circuit.
`magnetic circuit.
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`Page 12 of 17
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`

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`US 7,471,025 B2 US 7,471,025 B2
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`3 3
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`Other objects and features will be in part apparent and in Other objects and features will be in part apparent and in
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`part pointed out hereinafter. part pointed out hereinafter.
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`
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`BRIEF DESCRIPTION OF THE DRAWINGS BRIEF DESCRIPTION OF THE DRAWINGS
`
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`FIGS. 1A-1D illustrate portions of an exemplary stator FIGS. 1A-1D illustrate portions of an exemplary stator
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`assembly constructed in accordance with certain teachings of assembly constructed in accordance with certain teachings of
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`this disclosure prior to the rounding of such a stator assembly this disclosure prior to the rounding of such a stator assembly
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`into an annular form. into an annular form.
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`FIG. 2 generally illustrates an exemplary stator assembly FIG. 2 generally illustrates an exemplary stator assembly
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`constructed in accordance with certain teachings of this dis(cid:173)constructed in accordance with certain teachings of this dis(cid:173)
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`closure after it has been rounded into an annular form. closure after it has been rounded into an annular form.
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`FIGS. 3A and 3B generally illustrate certain aspects of a FIGS. 3A and 3B generally illustrate certain aspects of a
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`hinge assembly that may be used in connection with the hinge assembly that may be used in connection with the
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`exemplary embodiment of FIGS. 1A-1C and 2. exemplary embodiment of FIGS. 1A-1C and 2.
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`FIG. 4 generally illustrates aspects of a stator assembly FIG. 4 generally illustrates aspects of a stator assembly
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`formed in accordance with certain teachings of this disclosure formed in accordance with certain teachings of this disclosure
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`and a process for winding such a stator assembly. and a process for winding such a stator assembly.
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`FIGS. SA-SC generally illustrate an alternate embodiment FIGS. 5A-5C generally illustrate an alternate embodiment
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`of a stator assembly that may be used in connection with the 20 of a stator assembly that may be used in connection with the 20
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`exemplary winding process described in connection with exemplary winding process described in connection with
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`FIG. 4. FIG. 4.
`FIG. 6 generally illustrates an alternate embodiment of a
`FIG. 6 generally illustrates an alternate embodiment of a
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`hinge structure that may be used in connection with a stator hinge structure that may be used in connection with a stator
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`assembly as described herein. assembly as described herein.
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`FIGS. 7A and 7B generally illustrate alternate engage(cid:173)FIGS. 7A and 7B generally illustrate alternate engage(cid:173)
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`ment/locking structures that may be used with a stator con(cid:173)ment/locking structures that may be used with a stator con(cid:173)
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`structed in accordance with certain teachings herein to retain structed in accordance with certain teachings herein to retain
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`the stator assembly in an annular form. the stator assembly in an annular form.
`Corresponding reference characters indicate correspond- 30
`Corresponding reference characters indicate correspond- 30
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`ing parts throughout the drawings. ing parts throughout the drawings.
`
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`4 4
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`substantially identical laminations, typically stamped from substantially identical laminations, typically stamped from
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`steel. As best reflected in FIGS. 1B and 1C, each stack of steel. As best reflected in FIGS. 1B and 1C, each stack of
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`laminations defines a main yoke portion 21 and an extending laminations defines a main yoke portion 21 and an extending
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`tooth portion 22 that terminates in a "T" shaped portion 23. tooth portion 22 that terminates in a "T" shaped portion 23.
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`The yoke portion 21 of each stator stack defines an engage(cid:173)The yoke portion 21 of each stator stack defines an engage(cid:173)
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`ment projection 24 on one side of the yoke 21, and an engage(cid:173)ment projection 24 on one side of the yoke 21, and an engage(cid:173)
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`ment notch 25 on the opposing side of the yoke 21. The ment notch 25 on the opposing side of the yoke 21. The
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`engagement projection 24 and the engagement notch 25 are engagement projection 24 and the engagement notch 25 are
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`sized such that when adjacent stator segments 20 are brought sized such that when adjacent stator segments 20 are brought
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`10 together the engagement projection 24 will be received in the 10 together the engagement projection 24 will be received in the
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`engagement notch 25. This inhibits relative movement of the engagement notch 25. This inhibits relative movement of the
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`adjacent stator segments 20 in at least one direction. Notably, adjacent stator segments 20 in at least one direction. Notably,
`unlike prior art configurations where interlocking puzzle
`unlike prior art configurations where interlocking puzzle
`pieces serve to physically connect adjacent stator pieces
`pieces serve to physically connect adjacent stator pieces
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`15 together, the engagement notches and projections of the 15 together, the engagement notches and projections of the
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`exemplary embodiment do not perform that function. Absent exemplary embodiment do not perform that function. Absent
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`some other retaining structure, the engagement notches and some other retaining structure, the engagement notches and
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`projections will not physically interconnect or hold together projections will not physically interconnect or hold together
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`adjacent stator segment pieces. adjacent stator segment pieces.
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`In addition to defining engagement notches and projections In addition to defining engagement notches and projections
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`as described above, the yoke portions 21 of each stator seg(cid:173)as described above, the yoke portions 21 of each stator seg(cid:173)
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`ment also define a rear channel26. Rear channel26 is sized to ment also define a rear channel 26. Rear channel 26 is sized to
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`receive in a press-fit relationship a portion of the containment receive in a press-fit relationship a portion of the containment
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`structures 30 and 40 to help couple the stator segments to the structures 30 and 40 to help couple the stator segments to the
`25 containment structures. This is described in more detail
`25 containment structures. This is described in more detail
`below.
`below.
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`The "T' shaped portion 23 of each stator stack 20 defines The "T' shaped portion 23 of each stator stack 20 defines
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`an outer section 27 that upon complete assembly will be an outer section 27 that upon complete assembly will be
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`exposed and define a rotor bore and an inner section 28. The exposed and define a rotor bore and an inner section 28. The
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`inner section 28 is configured to help position and retain a inner section 28 is configured to help position and retain a
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`motor winding coil in a desired position with respect to the motor winding coil in a desired position with respect to the
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`stator tooth as described in more detail below. stator tooth as described in more detail below.
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`As described above, stator segments 20 are not physically As described above, stator segments 20 are not physically
`35 coupled together by hinges, interlocking puzzle pieces or 35 coupled together by hinges, interlocking puzzle pieces or
`
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`other features that are themselves part of the stator segments. other features that are themselves part of the stator segments.
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`To the contrary, no direct, stator segment-to-stator segment To the contrary, no direct, stator segment-to-stator segment
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`coupling exists between the stator segments 12. The two coupling exists between the stator segments 12. The two
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`containment structures 30 and 40 "sandwich" the stator seg-containment structures 30 and 40 "sandwich" the stator seg-
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`40 ments to form a relatively flexible stator assembly that is 40 ments to form a relatively flexible stator assembly that is
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`relatively easy to construct and wind. The stator assembly is relatively easy to construct and wind. The stator assembly is
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`held together in a form analogous to a "rack-of-ribs" where, held together in a form analogous to a "rack-of-ribs" where,
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`in an open arrangement as illustrated in FIG. 1A, the solid in an open arrangement as illustrated in FIG. lA, the solid
`stator segment assemblies 20 do n