II _.
`/; --
`
`PROVISIONAL APPLICATION COVER SHEET
`PROVISIONAL APPLICATION COVER SHEET
`This is a request for filing a PROVISIONAL APPLICATION under 37 CFR 1.53 (c)
`This is a request for filing a PROVISIONAL APPLICATION under 37 CFR 1.53 (c)
`
`I Type a plus sign (+) inside tbis box --+
`I Type a plus sign (+)inside this box--+
`
`+
`
`.,
`
`."
`_ _ >-I
`>-I
`0
`~0
`
`I Docket
`I Docket
`
`Number
`Number
`
`10823.0022.PZUSOO
`10823.0022.PZUSOO
`
`INVENTOR(s)/APPLICANT(s)
`INVENTOR(s)/APPLICANT(s)
`
`LAST NAME
`LAST NAME
`
`FIRST NAME
`FIRST NAME
`
`Sheeran
`Sheeran
`
`Rassoolkhani
`Rassoolkhani
`
`Michaels
`Michaels
`
`Kent
`Kent
`
`Payman
`Payman
`
`Paul
`Paul
`
`MIDDLE
`MIDDLE
`INITIAL
`INITIAL
`
`A.
`A.
`
`I +
`RESIDENCE (CITY AND EITH~ •
`RESIDENCE (CITY AND EITH~ ;.
`~~ ·~ Ulc..;a
`
`STATE OR FOREIGN COUNT~
`STATE OR FOREIGN COUNT~
`
`St. Louis, MO
`St. Louis, MO
`
`St. Louis, MO
`St. Louis, MO
`
`St. Louis, MO
`St. Louis, MO
`
`.~
`Ulc..;a
`. c..;a
`• c..;a
`~c:5'"
`~ood"
`\0 -
`\0 -
`CJ\II\SJI
`CJ\II\SJI
`..,
`CJ\~
`CJ\~
`....,
`- f-
`
`Segmented Stator With Improved Handling and Winding Characteristics and Method of Winding the Same
`Segmented Stator With Improved Handling and Winding Characteristics and Method of Winding the Same
`
`TITLE OF THE INVENTION (280 characters max)
`TITLE OF THE INVENTION (280 cbaracters max)
`
`CORRESPONDENCE ADDRESS
`CORRESPONDENCE ADDRESS
`Howrey Simon Arnold & White, LLP
`Howrey Simon Arnold & White, LLP
`750 Bering Drive
`750 Bering Drive
`Houston, Texas 77057-2198
`Houston, Texas 77057-2198
`USA
`USA
`
`ENCLOSED APPLICATION PARTS (check all that apply)
`ENCLOSED APPLICATION PARTS (check all that apply)
`
`~ Specification
`~ Specification
`~ Drawing(s)
`~ Drawing(s)
`
`Number of Pages 25
`Number of Pages 25
`Number of Sheets 2
`Number of Sheets .2
`
`D Small Entity Statement
`0 Small Entity Statement
`D Other (specify) __ _
`0 Otber (specify) __ _
`
`METHOD OF PAYMENT (check one)
`METHOD OF PAYMENT (check one)
`
`o A cbeck or money order is enclosed to cover the Provisional filing fees.
`D A check or money order is enclosed to cover the Provisional filing fees.
`~ The Commissioner is hereby authorized to charge filing fees and credit Deposit
`~ Tbe Commissioner is hereby authorized to charge filing fees and credit Deposit
`o Pursuant to 37 CFR 1.53(g) this provisional application is being filed witbout a filing fee.
`Account Number: 01-2508/l0823.0022.PZUSOO_should any fees be missing or deficient.
`Account Number: Ol-2508/10823.0022.PZUSOO_should any fees be missing or deficient.
`D Pursuant to 37 CFR 1.53(g) this provisional application is being filed without a filing fee.
`
`Please send the "Notice to File Missing Parts" form pursuant to 37 CFR 1.53(g).
`Please send the "Notice to File Missing Parts" form pursuant to 37 CFR 1.53(g).
`
`PROVISIONAL FILING FEE AMOUNT
`PROVISIONAL FILING FEE AMOUNT
`
`$150
`$150
`
`The invention was made by an agency of the United States Government or under a contract with an agency oftbe United States Government.
`The invention was made by an agency of the United States Government or under a contract with an agency oftbe United States Government.
`~ No_
`~ No.
`o
`D
`Yes, the name of the U.S. Government agency and the Government contract number are: _ __ _
`Yes, tbe name oftbe U.S. Government agency and the Government contract number are: __ _ _
`
`CERTIFICATE OF EXPRESS MAILING
`CERTIFICATE OF EXPRESS MAILING
`
`NUMBER EL 831851985 US
`NUMBER EL 831851985 US
`DATE OF DEPOSIT October 31. 2002
`DATE OF DEPOSIT October 31, 2002
`I hereby certify that this paper or fee is being deposited with the
`I hereby certify that this paper or fee is being depOSited with the
`United States Postal Service "EXPRESS MAIL POST OFFICE TO
`United States Postal Service "EXPRESS MAIL POST OFFICE TO
`ADDRESSEE" service under 37 C.F.R. 1.10 on the date indicated
`ADDRESSEE" service under 37 C.F.R 1.10 on the date indicated
`above and is addressed to: Box Provisional Patent Application.
`above and is addressed to: Box Provisional Patent Application,
`Commissioner for Patents. W s~ington D.~. 20231.
`Commissioner for Patents. W s~ington D.~. 20231.
`
`H: 505278(@TVSO!LDOC)
`H: 505278(@TV$01LDOC)
`
`R:0<~itt«2
`
`Billy C. Allen III
`Billy C. Allen III
`Reg. No. 46,147
`Reg. No. 46,14 7
`Howrey Simon Arnold & White, LLP
`Howrey Simon Arnold & White, LLP
`750 Bering Drive
`750 Bering Drive
`Houston, TX 77057-2198
`Houston, TX 77057-2198
`
`(713) 787-14/S !
`(713) 787-l4a 1
`Date: /0 Sf 0 L--
`Date: /0 3( 0 L--
`
`r
`r
`
`Page 1 of 37
`
`PETITIONERS' EXHIBIT 1018
`
`

`

`HOWRE'"
`HOWRe"'
`
`750 BERING DRIVE
`750 BERING DRIVE
`HOUSTON, TX 77057-2198
`HOUSTON, TX 77057-2198
`Iu .p f - - - - - - - - - - - - - - - - - - - PHONE 713.787.1400
`I l l .p l - - - - - - - - - - - - - - - - - - - PHONE 713.787.1400
`FAX 713.787.1440
`FAX 713.787.1440
`ATTORNEVS AT LAVV
`ATTORNEYS AT LAVV
`A LIMITED LIABILITY PARTNERSHIP
`A LIMITED LIABILITY PARTNERSHIP
`
`fiJi
`
`October 31,2002
`October 31, 2002
`
`FILE: 10823.0022.PZUSOO
`FILE: 10823.0022.PZUSOO
`
`CERTIFICATE OF EXPRESS MAILING
`CERTIFICATE OF EXPRESS MAILING
`NUMBER EL 831851985 US
`NUMBER EL 831851985 US
`DATE OF DEPOSIT October 31, 2002
`DATE OF DEPOSIT October 31, 2002
`I hereby certify that this paper or fee is being
`I hereby certify that this paper or fee is being
`deposited with the United States Postal Service
`deposited with the United States Postal Service
`"EXPRESS MAIL POST OFFICE TO
`"EXPRESS MAIL POST OFFICE TO
`ADDRESSEE" service under 37 C.F.R. 1.10 on
`ADDRESSEE" service under 37 C.F.R. 1.10 on
`the date indicated above and is addressed to: Box
`the date indicated above and is addressed to: Box
`Provisional Patent Application, Commissioner for
`Provisional Patent Application, Commissioner for
`Patents, Washington, DC 20 31.
`Patents, Washington, DC 20 31.
`
`BOX PROVISIONAL PATENT APPLICATION
`BOX PROVISIONAL PATENT APPLICATION
`Commissioner for Patents
`Commissioner for Patents
`Washington, DC 20231
`Washington, DC 20231
`Your Ref E-2397; us. Provisional Patent Application Entitled "Segmented Stator
`Your Ref E-2397; US. Provisional Patent Application Entitled "Segmented Stator
`With Improved Handling and Winding Characteristics and Method of Winding the
`With Improved Handling and Winding Characteristics and Method of Winding the
`Same" - Kent A. Sheeran, et a/.
`Same" - Kent A. Sheeran, et al.
`
`RE:
`RE:
`
`Sir:
`Sir:
`
`Transmitted herewith for filing is a provisional application coversheet, a 25-page provisional
`Transmitted herewith for filing is a provisional application coversheet, a 25-page provisional
`patent specification including 2 claims and an abstract. Also included are Figures 1-7 on 9
`patent specification including 2 claims and an abstract. Also included are Figures 1-7 on 9
`sheets. The specification and drawings constitute the application of Kent A. Sheeran, Payman
`sheets. The specification and drawings constitute the application of Kent A. Sheeran, Payman
`Rassoolkhani and Paul Michaels for the captioned invention. Applicants reserve the right to
`Rassoolkhani and Paul Michaels for the captioned invention. Applicants reserve the right to
`add inventors at a later stage.
`add inventors at a later stage.
`
`Pursuant to 37 C.F.R.- § 1.53(b)(2) and (d), the Applicants request the Patent and Trademark
`Pursuant to 37 C.F.R .. § 1.53(b)(2) and (d), the Applicants request the Patent and Trademark
`Office to accept this application and accord a serial number and filing date as of the date this
`Office to accept this application and accord a serial number and filing date as of the date this
`application is deposited with the U.S. Postal Service for Express Mail.
`application is deposited with the U.S. Postal Service for Express Mail.
`
`The Commissioner is authorized to charge the fee of $150.00 to Deposit Account No. 01-
`The Commissioner is authorized to charge the fee of $150.00 to Deposit Account No. 01-
`2508/10823.0022.PZUSOO. Should any additional fees under 37 C.F.R. §§ 1.16 to 1.21 be
`250S/I0S23.0022.PZUSOO. Should any additional fees under 37 C.F.R. §§ 1.16 to 1.21 be
`
`H: 50526S(@TVSOILDOC)
`H: 50526S(@TVSOILDOC)
`
`Page 2 of 37
`
`

`

`HOWREY
`
`ATTORNEYS AT LAW
`
`Commissioner for Patents
`Commissioner for Patents
`October 31, 2002
`October 31, 2002
`Page 2
`Page2
`
`required for any reason relating to the enclosed materials, the Commissioner is authorized to
`required for any reason relating to the enclosed materials, the Commissioner is authorized to
`deduct said fees from Deposit Account No. 01-2508/10823.0022.PZUSOO.
`deduct said fees from Deposit Account No. 01-2508/10823.0022.PZUSOO.
`
`Please date stamp and return the enclosed postcard to evidence receipt of this application.
`Please date stamp and return the enclosed postcard to evidence receipt of this application.
`
`Billy C. Allen III
`Billy C. Allen III
`Registration No. 46,147
`Registration No. 46,147
`
`RJM/tfh
`RJM/tfh
`Encl.
`Encl.
`
`H: 505268(@TV801!.DOC)
`H: 505268(@TV80ILDOC)
`
`Page 3 of 37
`
`

`

`l0823.0022.PZUSOOIEMCA
`10823.0022.PZUSOO/EMCA
`
`APPLICATION FOR UNITED STATES LETTERS PATENT
`APPLICATION FOR UNITED STATES LETTERS PATENT
`
`For
`For
`
`SEGMENTED STATOR WITH IMPROVED HANDLING AND WINDING
`SEGMENTED STATOR WITH IMPROVED HANDLING AND WINDING
`CHARACTERISTICS AND METHOD OF WINDING THE SAME
`CHARACTERISTICS AND METHOD OF WINDING THE SAME
`
`By
`By
`
`Kent A. Sheeran
`Kent A. Sheeran
`Payman Rassoolkhani
`Payman Rassoolkhani
`Paul Michaels
`Paul Michaels
`
`NUMBER: EL 831851985 US
`NUMBER: EL 831851985 US
`
`EXPRESS MAIL MAILING LABEL
`EXPRESS MAIL MAILING LABEL
`
`DATE OF DEPOSIT October 31, 2002
`DATE OF DEPOSIT October 31, 2002
`I hereby certify that this paper or fee is being deposited with the United States Postal Service
`I hereby certify that this paper or fee is being deposited with the United States Postal Service
`"EXPRESS MAIL POST OFFICE TO ADDRESSEE" service under 37 C.F.R. 1.10 on the date
`"EXPRESS MAIL POST OFFICE TO ADDRESSEE" service under 37 C.F.R. 1.10 on the date
`indicated above and is addressed to: Box Provisional Patent Application, Commissioner for Patents,
`indicated above and is addressed to: Box Provisional Patent Application, Commissioner for Patents,
`_ ) . ~ .
`- ) . ~ . '
`WashingtonD.C. 20231.
`·
`Washington D.C. 20231.
`
`~~
`~~
`
`H: 50179l(@R6NOI!.DOC)
`H: 501791(@R6N01!.DOC)
`
`1
`1
`
`Page 4 of 37
`
`

`

`BACKGROUND OF THE INVENTION
`BACKGROUND OF THE INVENTION
`
`The present disclosure relates to stator assemblies for electromagnetic machines
`The present disclosure relates to stator assemblies for electromagnetic machines
`
`and, more particularly, to segmented stator assemblies in which the stator is formed from
`and, more particularly, to segmented stator assemblies in which the stator is formed from
`
`a number of discrete stator stacks or segments with each stator segment comprising a
`a number of discrete stator stacks or segments with each stator segment comprising a
`
`yoke portion, a tooth portion and a coil winding wound about the tooth.
`yoke portion, a tooth portion and a coil winding wound about the tooth.
`
`While the use of distinct and separately wound stator segments provides some
`While the use of distinct and separately wound stator segments provides some
`
`benefits, it potentially increases the complexity and costs of manufacturing operations.
`benefits, it potentially increases the complexity and costs of manufacturing operations.
`
`For example, in many segmented stators the stator segments are wound individually and
`For example, in many segmented stators the stator segments are wound individually and
`
`one or more manufacturing step are required to appropriately interconnect all the
`one or more manufacturing step are required to appropriately interconnect all the
`
`individual stator coils to form the phase windings. In such conventional stator
`individual stator coils to form the phase windings. In such conventional stator
`
`assemblies, because the distinct and separately-wound stator segments are not coupled
`assemblies, because the distinct and separately-wound stator segments are not coupled
`
`together during the winding operation, some retention structure is required to hold the
`together during the winding operation, some retention structure is required to hold the
`
`stator segments together when they are formed into an annular stator. The requirements
`stator segments together when they are formed into an annular stator. The requirements
`
`for the coil interconnecting step, the materials and equipment required for the same, and
`for the coil interconnecting step, the materials and equipment required for the same, and
`
`the need for a secondary retention mechanism often require a significant capital
`the need for a secondary retention mechanism often require a significant capital
`
`investment in manufacturing equipment to manufacture such machines and significant
`investment in manufacturing equipment to manufacture such machines and significant
`
`material cost adders to the component costs of machines made in according to such
`material cost adders to the component costs of machines made in according to such
`
`processes.
`processes.
`
`In an effort to overcome some of the limitations associated with stator assemblies
`In an effort to overcome some of the limitations associated with stator assemblies
`
`having separately-wound stator segments as described above, approaches were developed
`having separately-wound stator segments as described above, approaches were developed
`
`wherein magnetically-interconnected stator segments were physically coupled to one
`wherein magnetically-interconnected stator segments were physically coupled to one
`
`another prior to the winding operation such that that the coils could be formed in an
`another prior to the winding operation such that that the coils could be formed in an
`
`interconnected manner. In known conventional approaches, the stator segments were
`interconnected manner. In known conventional approaches, the stator segments were
`
`H: 501791(@R6NOI!.DOC)
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`
`2
`2
`
`Page 5 of 37
`
`

`

`interconnected though the use of hinges, sometimes referred to as puzzle lock
`interconnected though the use of hinges, sometimes referred to as puzzle lock
`
`connections, or through the use of thin interconnecting bridges of magnetically permeable
`connections, or through the use of thin interconnecting bridges of magnetically permeable
`
`materials. Such interconnecting structure often requires relatively complex stator
`materials. Such interconnecting structure often requires relatively complex stator
`
`lamination constructions, which can increase the overall manufacturing costs for a
`lamination constructions, which can increase the overall manufacturing costs for a
`
`machine utilizing such a design. Moreover, the manufacturing steps required to couple
`machine utilizing such a design. Moreover, the manufacturing steps required to couple
`
`the distinct stator segments together via the hinge or puzzle lock structure increases the
`the distinct stator segments together via the hinge or puzzle lock structure increases the
`
`cost and complexity of the manufacturing process.
`cost and complexity of the manufacturing process.
`
`One limitation of stator assemblies using interconnecting puzzle pieces or bridges
`One limitation of stator assemblies using interconnecting puzzle pieces or bridges
`
`is that the stator assembly is often fairly inflexible and access to the stator teeth during
`is that the stator assembly is often fairly inflexible and access to the stator teeth during
`
`the winding operation is somewhat limited. These limitations can restrict the extent to
`the winding operation is somewhat limited. These limitations can restrict the extent to
`
`which magnetic wires can be placed in the stator to form the stator windings or, in other
`which magnetic wires can be placed in the stator to form the stator windings or, in other
`
`words, the "slot fill."
`words, the "slot fill."
`
`An alternate conventional approach for forming a "segmented stator like"
`An alternate conventional approach for forming a "segmented stator like"
`
`machine that does not require the use of hinges or puzzle locks relies upon the use of a
`machine that does not require the use of hinges or puzzle locks relies upon the use of a
`
`stator assembly formed from groupings of stator segments that are magnetically coupled
`stator assembly formed from groupings of stator segments that are magnetically coupled
`
`together by a thin, interconnecting bridge. Such a design is disclosed, for example, in
`together by a thin, interconnecting bridge. Such a design is disclosed, for example, in
`
`Japanese Patent B-30107085. Through the use of such a bridge, it appears possible to
`Japanese Patent B-3010708S. Through the use of such a bridge, it appears possible to
`
`have a grouping of three stator teeth that are coupled together magnetically by a bridge
`have a grouping of three stator teeth that are coupled together magnetically by a bridge
`
`element but that are opened to some degree allowing greater access to the stator teeth
`element but that are opened to some degree allowing greater access to the stator teeth
`
`and, thus, greater slot fill. One limitation of this approach is that the stator assembly will
`and, thus, greater slot fill. One limitation of this approach is that the stator assembly will
`
`typically require more than three stator teeth such that construction of the complete stator
`typically require more than three stator teeth such that construction of the complete stator
`
`assembly will require the use of multiple groupings of three stator segments, which
`assembly will require the use of multiple groupings of three stator segments, which
`
`necessitates multiple manufacturing steps of coupling the winding coils from the stator
`necessitates multiple manufacturing steps of coupling the winding coils from the stator
`
`H: 501791(@R6NOI!.DOC)
`H: 501791{@R6NOI!.DOC)
`
`3
`3
`
`Page 6 of 37
`
`

`

`groupings together and structure for coupling the multiple stator groupings to form an
`groupings together and structure for coupling the multiple stator groupings to form an
`
`annular stator. Such additional manufacturing steps and structure can significantly
`annular stator. Such additional manufacturing steps and structure can significantly
`
`increased the costs and manufacturing complexity associated with such stators.
`increased the costs and manufacturing complexity associated with such stators.
`
`The present disclosure describes several embodiments a stator assembly that are
`The present disclosure describes several embodiments a stator assembly that are
`
`designed to address the described and other limiting characteristics of conventional
`designed to address the described and other limiting characteristics of conventional
`
`segmented stator assemblies as described above.
`segmented stator assemblies as described above.
`
`H: 50179l(@R6NOI!.DOC)
`H: 501791(@R6NOI!.DOC)
`
`4
`4
`
`Page 7 of 37
`
`

`

`SUMMARY OF THE INVENTION
`SUMMARY OF THE INVENTION
`
`In accordance with one exemplary embodiment constructed in accordance with
`In accordance with one exemplary embodiment constructed in accordance with
`
`certain teachings of the present disclosure, a stator assembly is provided that may be
`certain teachings of the present disclosure, a stator assembly is provided that may be
`
`rounded into an annular form where the stator assembly comprises: a plurality of stator
`rounded into an annular form where the stator assembly comprises: a plurality of stator
`
`segments, each stator segment defining a yoke portion and a stator tooth; a containment
`segments, each stator segment defining a yoke portion and a stator tooth; a containment
`
`structure configured to position the stator segments relative to one another such that the
`structure configured to position the stator segments relative to one another such that the
`
`stator segments do not physically touch one another and such that no magnetic circuit
`stator segments do not physically touch one another and such that no magnetic circuit
`
`between adjacent stator segments is formed.
`between adjacent stator segments is formed.
`
`In accordance with one exemplary process that may be performed in accordance
`In accordance with one exemplary process that may be performed in accordance
`
`with certain teachings of the present disclosure a method for forming a segmented stator
`with certain teachings of the present disclosure a method for forming a segmented stator
`
`is disclosed where the method comprises the steps of: positioning a plurality of stator
`is disclosed where the method comprises the steps of: positioning a plurality of stator
`
`segments in a containment structure such that no magnetic circuit between adjacent stator
`segments in a containment structure such that no magnetic circuit between adjacent stator
`
`segments is formed; forming a winding coil about at least some of the stator segments;
`segments is formed; forming a winding coil about at least some of the stator segments;
`
`and deforming the containment structure to form an annular stator and to establish a
`and deforming the containment structure to form an annular stator and to establish a
`
`magnetic circuit between adjacent stator segments.
`magnetic circuit between adjacent stator segments.
`
`Other aspects of the present disclosure will be apparent from a review of the
`Other aspects of the present disclosure will be apparent from a review of the
`
`disclosure, the figures and the claims.
`disclosure, the figures and the claims.
`
`H: 501791(@R6NOII DOC)
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`5
`5
`
`Page 8 of 37
`
`

`

`BRIEF DESCRIPTION OF THE DRAWINGS
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`The description is presented with reference to the accompanying drawings in
`The description is presented with reference to the accompanying drawings in
`
`which:
`which:
`
`Figures IA-ID illustrate portions of an exemplary stator assembly constructed in
`Figures lA-lD illustrate portions of an exemplary stator assembly constructed in
`
`accordance with certain teachings of this disclosure prior to the rounding of such a stator
`accordance with certain teachings of this disclosure prior to the rounding of such a stator
`
`assembly into an annular form.
`assembly into an annular form.
`
`Figure 2 generally illustrates an exemplary stator assembly constructed in
`Figure 2 generally illustrates an exemplary stator assembly constructed in
`
`accordance with certain teachings of this disclosure after it has been rounded into an
`accordance with certain teachings of this disclosure after it has been rounded into an
`
`annular form.
`annular form.
`
`Figure 3A and 3B generally illustrate certain aspects of a hinge assembly that may
`Figure 3A and 3B generally illustrate certain aspects of a hinge assembly that may
`
`be used in connection with the exemplary embodiment of Figures lA-lC and 2.
`be used in connection with the exemplary embodiment of Figures IA-IC and 2.
`
`Figure 4 generally illustrates aspects of a stator assembly formed in accordance
`Figure 4 generally illustrates aspects of a stator assembly formed in accordance
`
`with certain teachings of this disclosure and a process for winding such a stator assembly.
`with certain teachings of this disclosure and a process for winding such a stator assembly.
`
`Figures SA-SC generally illustrate an alternate embodiment of a stator assembly
`Figures 5A-5C generally illustrate an alternate embodiment of a stator assembly
`
`that may be used in connection with the exemplary winding process described in
`that may be used in connection with the exemplary winding process described in
`
`connection with Figure 4.
`connection with Figure 4.
`
`Figure 6 generally illustrates an alternate embodiment of a hinge structure that
`Figure 6 generally illustrates an alternate embodiment of a hinge structure that
`
`may be used in connection with a stator assembly as described herein.
`may be used in connection with a stator assembly as described herein.
`
`Figure 7 A and 7B generally illustrate alternate engagement/locking structures that
`Figure 7 A and 7B generally illustrate alternate engagement/locking structures that
`
`may be used with a stator constructed in accordance with certain teachings herein to
`may be used with a stator constructed in accordance with certain teachings herein to
`
`retain the stator assembly in an annular form.
`retain the stator assembly in an annular form.
`
`H: 50179I(@R6NOI!.DOC)
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`
`6
`6
`
`Page 9 of 37
`
`

`

`DESCRIPTION OF EMBODIMENTS
`DESCRIPTION OF EMBODIMENTS
`
`Turning to the drawings and in particular to Figures IA-ID, an exemplary
`Turning to the drawings and in particular to Figures lA-lD, an exemplary
`
`embodiment of an improved segmented stator assembly 10 constructed in accordance
`embodiment of an improved segmented stator assembly 10 constructed in accordance
`
`with certain teachings of this disclosure illustrated
`with certain teachings of this disclosure illustrated
`
`Referring to Figures lA-Ie, the stator assembly 10 includes a plurality of
`Referring to Figures lA-IC, the stator assembly 10 includes a plurality of
`
`discrete, non-interconnected stator segments 20 sandwiched between two containment
`discrete, non-interconnected stator segments 20 sandwiched between two containment
`
`structures 30 and 40. In general, the stator segments 20 are formed form stacks of
`structures 30 and 40. In general, the stator segments 20 are formed form stacks of
`
`substantially identical laminations. The stator segments 20 are not directly
`substantially identical laminations. The stator segments 20 are not directly
`
`interconnected or magnetically coupled to one another. The stator segments are
`interconnected or magnetically coupled to one another. The stator segments are
`
`positioned within and held in place by pockets in the containment structures 30 and 40
`positioned within and held in place by pockets in the containment structures 30 and 40
`
`that are designed and shaped to receive the stator segments. The containment structures
`that are designed and shaped to receive the stator segments. The containment structures
`
`define flexible hinges that couple the pockets that contain the stator segments 20 to one
`define flexible hinges that couple the pockets that contain the stator segments 20 to one
`
`another. The containment structure is not magnetically conductive. During construction,
`another. The containment structure is not magnetically conductive. During construction,
`
`the independent stator segments 20 are sandwiched between the containment structures
`the independent stator segments 20 are sandwiched between the containment structures
`
`30 and 40. Then, while the stator segments are isolated from one another by the
`30 and 40. Then, while the stator segments are isolated from one another by the
`
`containment structures 30 and 40, wire is wound about the teeth of the stator segments to
`containment structures 30 and 40, wire is wound about the teeth of the stator segments to
`
`form stator coils and phase windings. After winding, the stator assembly 1 0 is rounded
`form stator coils and phase windings. After winding, the stator assembly lOis rounded
`
`into an annular form, bringing the stator segments into physical contact with one another
`into an annular form, bringing the stator segments into physical contact with one another
`
`and forming a closed magnetic circuit to form a completed stator.
`and forming a closed magnetic circuit to form a completed stator.
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`Details of the exemplary embodiment described above are provided below.
`Details of the exemplary embodiment described above are provided below.
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`The exemplary stator assembly 10 of Figures 1A-1D includes twelve stator
`The exemplary stator assembly 10 of Figures lA-ID includes twelve stator
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`segments 20, although alternate embodiments with a different number of stator segments
`segments 20, although alternate embodiments with a different number of stator segments
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`20 are envisioned and possible. The construction of each of the stator segments 20 is, in
`20 are envisioned and possible. The construction of each of the stator segments 20 is, in
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`H: 501791(@R6NOI!.DOC)
`H: 501791(@R6NOI!.DOC)
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`many respects, similar to the construction of the stator segments used in conventional
`many respects, similar to the construction of the stator segments used in conventional
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`segmented stator assemblies. In the illustrated embodiment, each stator segment 20 is
`segmented stator assemblies. In the illustrated embodiment, each stator segment 20 is
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`formed form a stack of substantially identical laminations, typically stamped from steel.
`formed form a stack of substantially identical laminations, typically stamped from steel.
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`As best reflected in Figures 1 Band 1 C, each stack of laminations defines a main yoke
`As best reflected in Figures 1 B and 1 C, each stack of laminations defines a main yoke
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`portion 21 and an extending tooth portion 22 that terminates in a "T" shaped portion 23.
`portion 21 and an extending tooth portion 22 that terminates in a "T" shaped portion 23.
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`In the illustrated embodiment the yoke portion 21 of each stator stack defines an
`In the illustrated embodiment the yoke portion 21 of each stator stack defines an
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`engagement projection 24 on one side of the yoke 21, and an engagement notch 25 on the
`engagement projection 24 on one side of the yoke 21, and an engagement notch 25 on the
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`opposing side of the yoke 21. The engagement projection 24 and the engagement notch
`opposing side of the yoke 21. The engagement projection 24 and the engagement notch
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`25 are geometrically sized such that, if adjacent stator segments 20 are brought together
`25 are geometrically sized such that, if adjacent stator segments 20 are brought together
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`the engagement projection 24 will be received in the engagement notch 25 to inhibit
`the engagement projection 24 will be received in the engagement notch 25 to inhibit
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`relative movement of the adjacent stator segments 20 in at least one direction. Notably,
`relative movement of the adjacent stator segments 20 in at least one direction. Notably,
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`unlike prior art configurations where interlocking puzzle pieces serve to physically
`unlike prior art configurations where interlocking puzzle pieces serve to physically
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`connect adjacent stator pieces together the engagement notches and projections of the
`connect adjacent stator pieces together the engagement notches and projections of the
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`exemplary embodiment do not perform that function. Absent some other retaining
`exemplary embodiment do not perform that function. Absent some other retaining
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`structure, the engagement notches and projections will not physically interconnect or hold
`structure, the engagement notches and projections will not physically interconnect or hold
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`together adjacent stator segment pieces.
`together adjacent stator segment pieces.
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`In addition to defining engagement notches and projections as described above, in
`In addition to defining engagement notches and projections as described above, in
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`the illustrated embodiment, the yoke portions 21 of each stator segment also define a rear
`the illustrated embodiment, the yoke portions 21 of each stator segment also define a rear
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`channel26 that- as described in more detail below- is sized to receive in a press-fit
`channel 26 that -
`as described in more detail below -
`is sized to receive in a press-fit
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`relationship a portion of the containment structures 30 and 40 to help couple the stator
`relationship a portion of the containment structures 30 and 40 to help couple the stator
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`segments to the containment structures.
`segments to the containment structures.
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`The "T" shaped portion 23 of each stator stack 20 defines an outer section 27 that
`The "T" shaped portion 23 of each stator stack 20 defines an outer section 27 that
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`-
`-
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`upon complete assembly - will be exposed and define a rotor bore and an inner
`upon complete assembly - will be exposed and define a rotor bore and an inner
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`H: 501791(@R6NOI!.DOC)
`H: 501791(@R6NOI!.DOC)
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`section 28. In the illustrated embodiment, the inner section 28 is slightly so as to help
`section 28. In the illustrated embodiment, the inner section 28 is slightly so as to help
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`position and retain a motor winding coil in a desired position with respect to the stator
`position and retain a motor winding coil in a desired position with respect to the stator
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`tooth as described in more detail below.
`tooth as described in more detail below.
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`As describ