Page 1 of 6
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`PETITIONERS' EXHIBIT 1020
`
`

`

`
`Ross Will Stun the World Ross Will Stun the World
`
`with Praise For with Praise For
`
`President Clinton ... President Clinton ...
`
`... before you'll find u better marketing opportunity
`... before you'll find u better marketing opportunity
`than ASSEMBLY Technology Expo '94!
`than ASSEMBLY Technology Expo '941
`
`Just imagine ... 20,000 proven buyers and product
`Just imagine ... 20,000 proven buyers and product
`
`specifiers ... jamming the exhibit floor ... checking out the specifiers ... jamming the exhibit floor ... checking out the
`
`latest in automatic assembly systems, power and hand tools, latest in automatic assembly systems, power and hand tools,
`
`machine vision, robotics, bar coding, fasteners, electrical/ machine vision, robotics, bar coding, fasteners, electrical/
`
`electronics and assembly hardware ... from more than electronics and assembly hardware .. . from more than
`
`325 manufacturers. 325 manufacturers.
`
`
`
`ASSEMBLY Technology Expo '94. ASSEMBLY Technology Expo '94.
`
`
`
`They'll see your competitors there ... will they see you? They'll see your competitors there ... will they see you?
`
`
`Complete and FAX the form on the back of this page- or Complete and FAX the form on the back of this page - or
`
`call LuRae Breyer at 800-323-5155 TODAY- for complete call LuRae Breyer at 800-323-5155 TODAY - for complete
`
`attendee profile statistics and exhibitor space options. attendee profile statistics and exhibitor space options.
`
`
`t'!.ASSEMB~ ~!.ASSEMB~
`1,. r TECHNOLOG
`I" r TECHNOlOG
`EXPOTM
`•
`•
`EXPOTM
`
`September 27 - 29,1994
`September 2 7 - 29, 1994
`Rosemont Convention Center
`Rosemont Convention Center
`Rosemont (Chicago), Illinois USA
`Rosemont (Chicago), Illinois USA
`
`Page 2 of 6
`
`

`

`
`PUBLISIDNG STAFF PUBLISmNG STAFF
`CHARLES SPAHR
`CHARLES SPAHR
`Group Pl\blisher
`Group Publisher
`DONALD E. HEGLAND
`DONALD E. HEGLAND
`Editor
`Editor
`ALLAN F. BENSON
`ALLAN F. BENSON
`Senio r Editor
`enior Editor
`WESLEY R. IVERSEN
`WESLEY R. IVERSEN
`Senio r Editor
`Senior Editor
`MARIE HAYES
`MARIE HAYES
`Production Editor
`Production Editor
`H. DEAN WILLIS
`H. DEAN WILLIS
`Art Di rector
`Art Director
`NANCY WYMAL'<I
`NANCY WYMAN
`Aclmin isu'ative Advertising
`Aclminisu·ative Advertising
`Coordinator
`Coordinator
`KAREN PANVINO
`KAREN PANVINO
`Production Coordinator
`Production Coordinator
`
`
`EDITORIAL ADVISORY BOARD EDITORIAL ADVISORY BOARD
`Richard P. Bodine Jr., V.P., The Bodine
`Richard P. Bodine Jr., V. P., The Bodine
`Corporation;Harry S. Brenner, president.
`Corporation;Harry S. Brenner, president.
`Almay Research And Testing Grou p; Peter
`Almay Research And Testing Group; Peter
`G. MacLaren, ConsultantJerry E. Kovach,
`G. MacLaren, ConsulrantJerry E. Kovach,
`President, Industrial Productivity Institute;
`President, Industrial Pcoductivity Institute;
`Frederick E. Graves , Engineering
`Frederick E. Graves, Engineering
`Consu Ita nt; Eugene Kerstin, Engineering
`Consultant; Eugene Kerstin, Engineering
`Consultant. Na tional Business ConSultanl~:
`Consultant. National Business Consultanl~:
`Henry Felski, Manager. Mfg. Engr., Stewart
`Henry FeIski. Manager. Mfg. Engr .. Stewart
`Wamer Corp .;WalterJ. Semmerling, Chief
`Wamer Corp.;WalterJ. Semmerllng, Chief
`Engineer, Mfg., C. E. Niehoff and Co.;Robert
`Engineer. Mfg., C.E. Niehoffand Co,;Robert
`Kegerreis, Director, Productivity Planning,
`Kegerreis, Director, Productivity Planning,
`Kelsey Hayes Co.
`Kelsey Hayes Co.
`
`
`CHILTON PUBLICATIONS CHILTON PUBLICATIONS
`A Capital Cities! ABC Publishing Group
`A Capital Cities/ ABC Publishing Group
`191 S. GalY Avenue
`191 S. Gaty Avenue
`Carol Stream, lL 60188
`Carol Stream, IL 60188
`Phone (708) 665-1000 Cable : HITCH POO
`Phone (708) 665-1000 Cable: HITCH PUB
`Telex: 72-0404 FAX: (708) 462-2225
`Telex: 72-0404 FAX: (708) 462-2225
`
`Leon C. Hufnagel. Jr., President
`Leon C. Hufnagel. Jr., President
`Donald w. Chestnut, Sr., Sr. VP. Ops./Admin.
`r., Sf. VP. o ps./Admin.
`Donald W. Chestnut,
`Christopher M. Sa vine, VP Finance
`Christopher M. Saville. VP Finance
`Andrew J. Weber. Sr. VP. Manufacturing Group
`Andrew]. WIeber. Sr. VP. Manufacturing Group
`
`Assembly© 1994 by Hitchcock Publishing Co.
`Assembly © 1994 by Hitchcock Publishing Co.
`All righls reserved. Assembly (ISSN 1050·8171)
`All rights reserved.Assembly CISSN 1050-8171)
`is published monthly except during August, and
`is published montbly except d uring AugUSt, and
`December b)' Hitchcock Publbhing Company,
`December by Hitchcock Publishing Company,
`1918. Gary Ave., Caro l Stream, IL 60188-2292.
`191 8. Gary Ave., Carol Stream, IL 60188-2292.
`Primed in the U.S.A. No pare of d1is publication
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`(0004-5063/ 94 $1.00) . One rear subscription
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`---------------------------------------------------------------
`
`EDITORIAL
`EDITORI AL
`
`
`
`No Blame, Big Gains No Blame, Big Gains
`
`
`
`R einvention. It's today's buzz word. President Reinvention. It's today's buzz word. President
`
`Clinton talks about reinventing big government.
`Clinton talks about reinventing big government.
`
`And companies from IBM to mom-and-pop And companies from IBM to mom-and-pop
`
`enterprises are reengineering themselves(cid:173)enterprises are reengineering themselves-(cid:173)
`
`redesigning processes, structure, and culture-to redesigning processes, structure, and culture--to
`
`compete in a tough economy. compete in a tough economy.
`
`To steer a proper course, a company needs to To steer a proper course, a company needs to
`
`understand its most detailed workings, says Leonard understand its most detailed workings, says Leonard
`
`Bertain. He heads a productivity consulting firm and Bertain. He heads a productivity con ulting firm and
`
`authored The New Turnaround, a "business novel" authored Tbe New Turnarou.nd, a "business novel"
`
`based on his experiences. based on his experiences.
`
`"A company needs to understand the degree to "A company needs to understand the degree to
`which its current processes and culture are a part of which its current processes and culture are a palt of
`
`
`the problem," says Dr. Bertain. "Only then can meaningful reinvention occur." the problem," says Dr. Bertain. "Only then can meaningful reinvention occur. "
`
`He feels that many companies are confused by the business cultures they have He feels that many companies are confused by the business cultures they have
`
`created. The ideas that helped them grow and succeed in the past now hinder created. The ideas that helped them grow and succeed in the past now hinder
`them.
`them.
`
`"Big companies achieved revenue growth, but didn't grow in their ability to "Big companies achieved revenue growth, but didn't grow in their ability to
`
`effectively adapt to change. And small companies that copied big companies have effectively adapt to change. And small companies that copied big companies have
`
`often downsized in lock-step with them," Dr. Bertain explains. often downsized in lock-step with them," Dr. Bertain explains.
`
`Lack of ideas doesn't deter companies from becoming high performers. \Vhat's Lack of ideas doesn't deter companies from becoming high performers. What's
`
`lacking, he says, is a clear understanding of what to change and how to lacking, he says, is a clear understanding of what to change and how to
`in1plement change.
`implement change.
`
`One of the biggest barriers to becoming competitive, Dr. Bertain continues, is One of the biggest barriers to becoming competitive, Dr. Bertain continues, is
`
`that people spend too much time placing blame, and defending sacred cows. that people spend too much time placing blame, and defending sacred cows.
`
`"When management and labor are not pointing fingers at each other, they are "When management and labor are not pointing fingers at each other, they are
`pointing at unfair foreign competition, inequitable trade practices, government
`pointing at unfair foreign competition, ineqUitable trade practices, government
`regulation, lack of government regulation, over-hyped productivity philosophies(cid:173)
`regulation, lack of government regulation, over-hyped productivity philosophies(cid:173)
`
`and just about anything else that will distract attention from industry's collective and just abou t anything else that will dist.ract attention from industry's collective
`
`responsibility," Dr. Bertain asserts. responsibility," Dr. Bertain asserts.
`
`"TQM, ]IT, SPC, TOC, and synchronous manufacturing are all useful tools for "TQM, JIT, SPC, TOC, and synchronous manufacturing are all useful tools for
`
`dealing with the demands of the competitive global marketplace. They are not the dealing with the demands of the competitive global marketplace. They are not the
`
`problem. It is the assumptions built into our business culture that have tainted our problem. It is the assumptions built into our business culture that have tainted our
`
`adaptation of these improvement philosophies. " adaptation of these improvement philosophies. "
`
`For example, he says, the majority of American managers feel that thinking is For example, he says, the majority of American managers feel that thinking is
`
`not part of most workers' job descriptions. Dr. Bertain proposes a prerequisite for not part of most workers' job descriptions. Dr. Bertain proposes a prerequisite for
`
`meaningful, long-term improvement: a strong, no-blame approach "to set aside meaningful, long-term improvement: a strong, no-blame approach "to set aside
`
`fears, and facilitate progress. " fears, and facilitate progress. "
`
`Perhaps your company should encourage all employees to work together in a Perhaps your company should encourage all employees to work together in a
`
`positive, no-blame environment to reinvent the kind of culture that you need to positive, no-blame environment to reinvent the kind of culture that you need to
`
`succeed. There is nothing to lose, except the barriers between you and the big succeed. There is nothing to lose, except the barriers between you and the big
`
`gains that come from no blame. gains that come from no blame.
`
`May/94 ASSEMBLY-5
`May/ 94 ASSEMBL Y-5
`
`Page 3 of 6
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`

`

`ELECTRICAL MANUFACTURING AND CoiL WINDING
`ELECTRICAL MANUFACTURING AND COIL WINDING
`
`
`Molded Parts Molded Parts
`
`Speed Motor Assembly Speed Motor Assembly
`
`
`Motor manufacturers increasingly use engineering plastics Motor manufacturers increasingly use engineering plastics
`to develop stator advancements.
`to develop stator advancements.
`
`W.J. Hassink
`W.J. Hassink
`Senior Development Specialist
`Senior Development Specialist
`W.E. Kenney
`W.E. Kenney
`Senior Design Specialist
`Senior Design Specialist
`J. Deeble
`J. Deeble
`Laboratory Representative
`Laboratory Representative
`DuPont Polymers
`DuPont Polymers
`Wilmiogton, DE
`Wilmiogton, DE
`
`
`are used in stators employing conventional are used in stators employing conventional
`
`flexible lot insulation. flexible slot insulation.
`
`Motor builders can further economize Motor builders can further economize
`
`on labor input by eliminating flexible slot on labor input by eliminating flexible slot
`
`insulation, and by integrating that function insulation, and by integrating that function
`
`into a combination end/ slot insulating com(cid:173)into a combination end/ slot insulating com(cid:173)
`ponent. The parts shown in Figure 1 reflect ponent. The parts shown in Figure 1 reflect
`
`
`this approach. They are used in tl1e stator this approach. They are used in tile stator
`
`(shown partially assembled in Figure 2) for (shown partially assembled in Figure 2) for
`
`a universal motor that powers Miele of a universal motor that powers Miele of
`
`Germany washing machines. Germany washing machines.
`
`The larger, more complex Miele compo(cid:173)The larger, more complex Miele compo(cid:173)
`
`nents integrate end and slot insulation, nents integrate end and slot insulation,
`termination holders, and provisions for snap(cid:173)termination holders, and provisions for snap(cid:173)
`
`
`lock assembly. Anod1er part at the opposite lock assembly. Anotl1er part at the opposite
`
`end of tl1e lamination stack from the larger end of tile lamination stack from tl1e larger
`
`component has integral snap-locking de(cid:173)component has integral snap-locking de(cid:173)
`
`tents and coil supports, too. tents and coil supports, too.
`
`Both components are injection molded Both components are injection molded
`
`in an unreinforced 6,6 nylon resin, part of in an unreinforced 6,6 nylon reSin, part of
`a pretested, preapproved UL Class B (130°C)
`a pretested, preapproved UL Class B (130°C)
`
`system evaluated in according to IEC Pub(cid:173)system evaluated in according to IEC Pub(cid:173)
`
`lication 85. This saved the manufacturer lication 85. This saved me manufacturer
`
`time in obtaining necessaty approvals to time in obtaining necessalY approvals to
`meet electrical safety requirements of vari(cid:173)
`meet electrical safety requirements of vari(cid:173)
`ous countries.
`ous countries.
`
`Encapsulation: one-step production
`Encapsulation: one-step production
`
`Given sufficient volume to recover tool(cid:173)Given sufficient volume to recover tool(cid:173)
`ing costs, insert moldirtg technology offers
`ing costs, insert molding technology offers
`
`the ultimate in design ing stators for a mini(cid:173)tl1e ultimate in designing stators for a mini(cid:173)
`mum of assembly steps and cost. The
`mum of a sembly steps and cost. The
`p rocess involves placing the steel lamina(cid:173)
`process involves placing the steel lamina(cid:173)
`
`tions in an injection mold, and then filling tions in an injection mold , and tllen filling
`
`the mold with tl1ermoplastic material. In a the mold with tl1ermoplastic material. In a
`single step, the process locks the lamina(cid:173)
`single step, the process locks the lamina(cid:173)
`tions together and forms end and slot
`lot
`tions together and forms end and
`insulation, coil supports, and assembly fea-
`insulation, coil supports, and assembly fea-
`
`Figure 1: Molded stator parts for washer
`Figure 1: Molded stator parts for washer
`motor.
`motor.
`
`Multifunctional stator parts
`Multifunctional stator parts
`
`Separately molded stator components Separately molded stator components
`
`of engineering plastics offer several ways of engineering plastics offer several ways
`
`to cut assembly costs, while allowing use to cut assembly costs, while allowing use
`of the same parts in different motors.
`of tile same parts in different motors.
`
`Recently, several motor manufacturers Recently, several motor manufacturers
`
`have adopted molded end insulators with have adopted molded end insulators with
`integral pockets for automated termina(cid:173)
`integral pockets for automated tennina(cid:173)
`tion. The pockets offer a notch or slot to
`tion. The pockets offer a notch or slot to
`hold the magnet wire end while a machine
`hold the magnet wire end while a machine
`inserts a metal terminal. Such components
`inserts a metal terminal. Such components
`
`Figure 2: Assembled stator for washer
`Figure 2: Assembled stator for washer
`motor.
`motor.
`
`
`
`R ecent innovations in motor design Recent innovations in motor design
`
`use engineering plastics. For sta(cid:173)use engineering plastics. For sta(cid:173)
`
`tors, motor manufacturers are fol(cid:173)
`tors, motor manufacturers are fol(cid:173)
`lowing two main paths to reduce
`lowing two main paths to reduce
`costs and improve reliability with engi(cid:173)
`costs and improve reliability with engi(cid:173)
`neering plastics. One path involves sepa(cid:173)
`neering plastics. One path involves sepa(cid:173)
`rately molded multifunctional components;
`rately molded multifunctional components;
`the other employs insert molding to encap(cid:173)
`the other employs insert molding to encap(cid:173)
`
`sulate the stator, while simultaneously build(cid:173)sulate the stator, while simultaneously build(cid:173)
`
`ing in assembly functions. ing in a sembly functions.
`
`Driven by needs to hold down costs Driven by needs to hold down costs
`and improve reliability, motor manufactur(cid:173)and improve reliability, motor manufactur(cid:173)
`
`ers increasingly integrate engineering plas(cid:173)
`ers increasingly integrate engineering plas(cid:173)
`tics into their products. In papers pre(cid:173)
`tics into their products. In papers pre(cid:173)
`
`sented at recent EMCWA conferences, we sented at recent EMCWA conferences, we
`
`have reported innovations in several areas: have reported innovations in several areas:
`• Multifunctional end brackets that inte(cid:173)
`• Multifunctional end brackets that inte(cid:173)
`grate insulation, structural, bearing, and
`grate insulation, structura l, bearing, and
`assembly features;
`assembly features;
`• Bearings that eliminate separate lu(cid:173)
`• Bearings that eliminate separate lu(cid:173)
`brication;
`brication;
`• Rotors and stators using molded com(cid:173)
`• Rotors and stators using molded com(cid:173)
`ponents to replace paper, film, thermosets,
`ponents to replace paper, film , thermosets,
`or other traditional materials.
`or other tracUtional materials.
`
`Recently the pace of innovation has Recently the pace of innovation has
`
`quickened in stator design and construc(cid:173)quickened in stator design and construc(cid:173)
`
`tion. Producing traditional stator designs is tion. Producing traditional stator designs is
`
`highly labor intensive. It requires handling highly labor intensive. It requires handling
`
`and placement of flexible slot insulators, and placement of flexible slot insulators,
`
`and other components such as pultruded and other components such as pultruded
`
`thermoset pins or tie cords, to secure field thermoset pins or tie cords, to secure field
`coils to laminations. Terminating the field
`coils to laminations. Terminating the field
`coil's magnet wire to a lead w ire is often a
`coil's magnet wire to a lead wire is often a
`manual operation.
`manual operation.
`To reduce stator assembly costs, motor
`To reduce stator assembly costs, motor
`makers are increasingly turning to engi(cid:173)
`makers are increasingly turning to engi(cid:173)
`neering plastics-either separately molded
`neering plastics-either separately molded
`components or encapsulation materials.
`components or encapsulation materials.
`
`34-ASSEMBLY May I 94
`34-ASSEMBL Y May / 94
`
`Page 4 of 6
`
`

`

`ELECTRICAL MANUFACTURING AND CoiL WINDING
`ELECTRICAL MANUFACTURING AND COIL WINDING
`
`tures such as winding guides, terminal
`tures such as winding guides, terminal
`holders, screw bosses, and mOlmting brack(cid:173)
`holders, screw bosses, and mounting brack(cid:173)
`ets components.
`ets components.
`Besides cutting costs, insert molding is
`Besides cutting costs, insert molding is
`simple and relatively easy to control. By
`simple and relatively easy to control. By
`eliminating various separate components
`eliminating various separate components
`and operations, it avoids multiplication of
`and operations, it avoids multiplication of
`tolerances, and thus promotes consistency
`tolerances, and thus promotes consistency
`of quality and product reliability.
`of quality and product reliability.
`Several examples show how motor
`Several examples show how motor
`manufacturers use insert molding to achieve
`manufacturers use insert molding to achieve
`the features and benefits of thermoplastic
`the features and benefits of thermoplastic
`encapsulation.
`encapsulation.
`• AC induction motors. The stators
`• AC induction motors. The stators
`shown in Figures 3 and 4 serve in AC
`shown in Figures 3 and 4 se1ve in AC
`induction motors for fans for commercial
`induction motors for fans for commercial
`refrigeration equipment. Both were devel(cid:173)
`refrigeration equipment. Both were devel(cid:173)
`oped by Electric Motors and Specialties,
`oped by Electric Motors and Specialties,
`Inc. (EM&S), Garrett, IN.
`Inc. (EM&S) , Garrett, IN.
`The unit in Figure 3 is for a 10 W, split-
`The unit in Figure 3 is for a 10 W, split-
`
`
`Figure 3: Encapsulated stator for 10 W Figure 3: Encapsulated stator for 10 W
`split capacitor motor.
`split capacitor motor.
`
`capacitor motor for condenser fans. The
`capacitor motor for condenser fans. The
`slot/end encapsulation part has integral
`slot/ end encapsulation part has integral
`po ts that double as supports for a terminal
`po ts that double as supports for a terminal
`board and as winding gUides.
`board and a winding gu ides.
`EM&S formerly encapsulated an earlier
`EM&S formerly encapsulated an earlier
`version of this stator with an epoxy pow(cid:173)
`version of this stator with an epoxy pow(cid:173)
`der system. Switching to thermoplastic
`der system. Switching to thermoplastic
`encapsulation reduced costs by elin1inat(cid:173)
`encapsulation reduced costs by eliminat(cid:173)
`ing the need to tumble-finish and preheat
`ing the need to tumble-finish and preheat
`the laminate cores prior to coating.
`the laminate cores prior to coating.
`The stator in Figure 4 is for a 25 W
`The stator in Figure 4 is for a 25 W
`shaded pole 1110tOr. In addition to end and
`shaded pole motor. In addition to end and
`slot insulation, the one-piece design incor(cid:173)
`slot insulation, the one-piece design incor(cid:173)
`porates contoured winding slots for accu(cid:173)
`porates contoured winding slots for accu(cid:173)
`rate placement of windings, and permits
`rate placement of windings, and permits
`
`
`Figure 4: Encapsulated stator for 25 W Figure 4: Encapsulated stator for 25 W
`
`shaded pole motor. shaded pole motor.
`
`effective use of slot space. Termination
`effective use of slot space. Termination
`holders are also integrated in the design.
`holders are also integrated in the design.
`. In a previous construction, the stator
`· In a previous construction, the stator
`used a paper/ film composite for slot insu(cid:173)
`used a paper/ film composite for slot insu(cid:173)
`lation, and separate parts for coil supports,
`lation, and separate parts for coil supports,
`end insulation, and termination holders.
`end insulation, and termination holders.
`Thermoplastic encapsulation reduced part
`Thermoplastic encapsulation reduced part
`and assembly costs while improving qual(cid:173)
`and assembly costs while in1proving qual(cid:173)
`ity, says EM&S.
`ity, says EM&S.
`Both stator designs are encapsulated
`Both stator designs are encapsulated
`with a nylon resin. It provides high produc(cid:173)
`with a nylon resin. It provides high produc(cid:173)
`tivity in the insert molding process, and is
`tivity in the insert molding process, and is
`part of a pre-approved insulation system
`part of a pre-approved insu lation system
`for Class B (130°C) service under the UL
`for Class B (130°C) service under the UL
`1446 standard .
`1446 standard.
`• Universal motor. The stator shown
`• Universal motor. The stator shown
`at the right in Figure 5 is for a universal
`at the right in Figure 5 is for a universal
`motor used in a meat grinder produced by
`motor used in a meat grinder produced by
`S.E.B. of France. The encapsulation mate(cid:173)
`S.E.B. of France. The encapsulation mate(cid:173)
`rial not only provides end insulation but
`rial not only provides end insulation but
`
`
`Figure 5: Encapsulated stator, end bracket, Figure 5: Encapsulated stator, end bracket,
`
`and spider for meat grinder motor. and spider for meat grinder motor.
`
`fulfills stru ctural and assembly functions.
`fulfills stru ctural and assembly functions.
`The coil supports at both ends have
`The coil supports at both ends have
`integral flanges to fix the magnet wire's
`integral flanges to fix the magnet wire's
`position. Slotted termination pockets hold
`position. Slotted termination pockets hold
`magnet wire ends and are configured to
`magnet wire ends and are configured to
`hold standard metal terminals. Through
`hold standard metal terminals. Through
`holes facilitate subsequent assembly of the
`holes facilitate subsequent assembly of the
`stator to end brackets.
`stator to end brackets.
`The resin used is a thermoplastic poly(cid:173)
`The resin used is a thermoplastic poly(cid:173)
`ester, flame-retardant material based on
`ester, flame-retardant material based on
`
`polyethylene terephthalate (PET). It is patt polyethylene terephthalate (PET). It is pan
`of preapproved UL 1446 systems for ser(cid:173)
`of preapproved UL 1446 systems for ser(cid:173)
`vice up to Class N (200°C). S.E.B.'s meat
`vice up to Class N (200°C). S.E.B. 's meat
`grinder motor is engineered for Class H
`grinder motor is engineered for Class H
`(I80°C) service.
`(180°C) se1vice.
`The end bracket and spider shown at
`The end bracket and spider shown at
`the left and center of Figure 5 are injection
`the left and center of Figure 5 are injection
`molded of the same material. The bracket
`molded of the same material. The bracket
`design also incorporates nWl1erous molded(cid:173)
`design also incorporates mm1erous molded(cid:173)
`in functions. They include an integral bear-
`in functions. They include an integral bear-
`
`
`Figure 6: New brushless DC washer motor Figure 6: New brushless DC washer motor
`
`uses large encapsulated components. uses large encapsulated components.
`
`ing pocket, retainer posts for the brush
`ing pocket, retainer posts for the brush
`spring, fingers for a capacitor, bmsh wells,
`spring, fingers for a capacitor, bntsh wells,
`several screw bosses, and a mounting
`several screw bosses, and a mounting
`bracket.
`bracket.
`
`• Novel DC brushless motor. New • Novel DC brushless motor. New
`Zealand's leading appliance maker, Fisher
`Zealand's leading appliance maker, Fisher
`& Paykel Co., has implemented automa(cid:173)
`& Paykel Co., has implemented automa(cid:173)
`tion opportunities of insert molding in a
`tion opportunities of insert molding in a
`radically new kind of bmshless DC motor.
`radically new kind of brushless DC motor.
`Used in washing machines, it (Figure 6) is
`Used in washing machines, it (Figure 6) is
`electronically controlled and directly drives
`electronically controlled and directly drives
`the washer's agitator and spin bowl through
`the washer's agitator and spin bowl through
`a patented clutch. This eliminates a com(cid:173)
`a patented clutch. This eliminates a com(cid:173)
`plex gear case required with a fixed-speed
`plex gear case required with a fixed- peed
`AC motor.
`AC motor.
`
`May I 94 ASSEMBLY-35
`May / 94 ASSEMBLY-35
`
`Page 5 of 6
`
`

`

`ELECTRICAL MANuFACTURING AND CoiL WINDING
`ELECTRICAL MANUFACTURING AND COIL WINnING
`
`
`This dish-shaped component measures This dish-shaped component measures
`about 27 em (10.5 in.) in diameter and
`about 27 cm (10.5 in.) in diameter and
`
`rotates around the stator. Integrally molded rotates around the stator. Integrally molded
`teeth in the hub mate with the spline end teeth in the hub mate with the spline end
`
`of a steel shaft that spins the \vasher tub
`of a steel shaft that spins the \vasher tub
`and moves the agitator.
`and moves the agitator.
`
`Polyester resins based on PET are used Polye ter resins based on PET are used
`
`for both components. The rotor resin ha for both components. The rotor resin has
`
`45% glass reinforcement. The stator mate(cid:173)45% glass reinforcement. The stator mate(cid:173)
`
`rial is a flame-retardant formula with 43% rial is a flame-retardant formula with 43%
`
`reinforcement. reinforcement.
`
`Both formulas provide high stiffness Both formulas provide high stiffness
`
`and strength plus creep resistance required and strength plus creep resistance required
`
`in the large, heavy assemblies. In the stator, in the large, heavy assemblies. In the stator,
`
`the thermoplastic material is subject to the thermoplastic material is subject to
`
`hefty static loads in supporting about 3 kg hefty static loads in supporting about 3 kg
`
`(6.6 lb) of windings and steel laminations. (6.6 Ib) of windings and steel laminations.
`
`The rotor wid1stands dynamic torsional The rotor withstands dynamic torsional
`and radial Loading as it oscillates at variable
`and radial Loading as it oscillates at variable
`speeds in a 200° arc during agitation cycles,
`speeds in a 2000 arc during agitation cycles,
`and whirls up to 1100 rpm during spin
`and whirls up to 1100 rpm during spin
`cycles.
`cycles.
`
`Although F&P's patented motor is an Although F&P's patented motor is an
`
`unusual design, it holds valuable lessons unusual design, it holds valuable lessons
`
`for od1er types of motors. It is an outstand(cid:173)for other types of motors. It is an outstand(cid:173)
`
`ing example of consolidating multiple func-ing example of consolidating mUltiple func-
`
`
`Figure 8: Encapsulated rotor for brushless Figure 8: Encapsulated rotor for brush less
`
`DC washer motor. DC washer motor.
`
`
`tions in engineering plastics parts-and it tions in engineering plastics parts-and it
`
`underscores the value of rethinking tradi(cid:173)underscores the value of rethinking tradi(cid:173)
`tional motor design.
`tional motor design.
`Motor manufacturers in the U.S. and
`Motor manufacturers in the U.S. and
`
`abroad are reducing costs and improving abroad are reducing costs and inlproving
`the reliability of stators by building mul(cid:173)
`the reliability of stators by building mul(cid:173)
`
`tiple insulation, assembly, and structural tiple insulation, assembly, and structural
`
`functions into engineering-plastics compo(cid:173)functions into engineering-plastics compo(cid:173)
`
`nents. Benefits derive from eid1er sepa(cid:173)nents. Benefits derive from either sepa(cid:173)
`
`rately molded components or encapsula(cid:173)rately molded components or encapSUla(cid:173)
`tion techniques. The choice depends on tion techniques. The choice depends on
`
`production volume and other factors such
`production volume and other factors such
`0
`as plant layout and motor design.
`as plant layout and motor design.
`0
`
`
`Figure 7: Encapsulated stator for Figure 7: Encapsulated stator for
`
`brushless DC washer motor. brushless DC washer motor.
`
`
`Wheel-shaped, the motor's stator (Fig(cid:173)Wheel-shaped, the motor's stator (Fig(cid:173)
`ure 7) measures about 25 em (9.8 in.)
`ure 7) measures about 25 cm (9.8 in.)
`across. Its lamination stack resembles a
`across. Its lamination stack resembles a
`specially profiled ring. When placed in the
`specially profiled ring. When placed in the
`mold, the insert molding process produces
`mold, the insert molding process produces
`the stator's support structure, ground insu(cid:173)
`the stator's support struct