US 20040084988A1
`
`(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2004/0084988 A1
`(43) Pub. Date: May 6, 2004
`
`Sheeran et al.
`
`(54) SEGMENTED STATOR WITH IMPROVED
`HANDLING AND WINDING
`CHARACTERISTICS AND METHOD OF
`WINDING THE SAME
`
`(76)
`
`Inventors: Kent A. Sheeran, Festus, MO (US);
`Payman Rassoolkhani, Maryland
`Heights, MO (US); Paul G. Michaels,
`St. Louis, MO (US)
`
`Correspondence Address:
`HOWREY SIMON ARNOLD & WHITE, LLP
`750 Bering Drive
`Houston, TX 77057-2198 (US)
`
`(21) Appl. No.:
`
`10/427,450
`
`(22)
`
`Filed:
`
`Apr. 30, 2003
`
`Related US. Application Data
`
`(60) Provisional application No. 60/422,676, filed on Oct.
`31, 2002.
`
`Publication Classification
`
`Int. Cl.7 ............................... H02K 1/18; H02K 1/28
`(51)
`(52) U.S.Cl.
`.............................................................. 310/218
`
`(57)
`
`ABSTRACT
`
`Astator assembly that may be rounded into an annular form
`is disclosed that
`includes a plurality of stator segments
`where each stator segment defines a yoke portion and a
`stator tooth and a containment structure configured to posi-
`tion the stator segments relative to one another such that the
`stator segments do not physically touch one another and
`such that no magnetic circuit between adjacent stator seg-
`ments is formed. Also disclosed is a method for forming a
`segmented stator, involving the steps of positioning a plu-
`rality of stator segment 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; and deforming the containment structure to
`form an annular stator and to establish a magnetic circuit
`between adjacent stator segments.
`
`
`
`
`
`Am. Honda v. IV II - IPR2018-006l9
`
`PET_HONDA_1008—0001
`
`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1008-0001
`
`

`

`Patent Application Publication May 6, 2004 Sheet 1 0f 9
`
`US 2004/0084988 A1
`
`
`
`Am. Honda V. IV 11 - IPR2018-00619
`
`PET_HONDA_1008—0002
`
`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1008-0002
`
`

`

`Patent Application Publication May 6, 2004 Sheet 2 0f 9
`
`US 2004/0084988 A1
`
`FIG.1B
`
`Am. Honda V. IV 11 - IPR2018-00619
`
`PET_HONDA_1008-0003
`
`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1008-0003
`
`

`

`Patent Application Publication May 6, 2004 Sheet 3 0f 9
`
`US 2004/0084988 A1
`
`FIG.1D
`
`FIG.1C
`
`Am. Honda V. IV 11 - IPR2018-00619
`
`PET_HONDA_1008—0004
`
`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1008-0004
`
`

`

`Patent Application Publication May 6, 2004 Sheet 4 0f 9
`
`US 2004/0084988 A1
`
`FIG.2
`
`Am. Honda V. IV 11 - IPR2018-00619
`
`PET_HONDA_1008-0005
`
`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1008-0005
`
`

`

`Patent Application Publication
`
`May 6, 2004 Sheet 5 0f 9
`
`US 2004/0084988 A1
`
`
`
`Am. Honda V. IV 11 - IPR2018-00619
`
`PET HONDA 1008—0006
`
`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1008-0006
`
`

`

`Patent Application Publication
`
`May 6, 2004
`
`Sheet 6 0f 9
`
`US 2004/0084988 A1
`
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`PET_HONDA_1008—0007
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`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1008-0007
`
`

`

`Patent Application Publication
`
`May 6, 2004 Sheet 7 0f 9
`
`US 2004/0084988 A1
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`PET HONDA 1008-0008
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`PET_HONDA_1008-0008
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`Patent Application Publication May 6, 2004 Sheet 8 0f 9
`
`US 2004/0084988 A1
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`PET_HONDA_1008—0009
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`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1008-0009
`
`

`

`Patent Application Publication May 6, 2004 Sheet 9 0f 9
`
`US 2004/0084988 A1
`
`FIG.7B
`
`FIG.6
`
`Am. Honda V. IV 11 - IPR2018-00619
`
`PET_HONDA_1 008-0010
`
`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1008-0010
`
`

`

`US 2004/0084988 A1
`
`May 6, 2004
`
`SEGMENTED STATOR WITH IMPROVED
`HANDLING AND WINDING CHARACTERISTICS
`AND METHOD OF WINDING THE SAME
`
`PRIORITY CLAIM
`
`[0001] This application claims the benefit of US. Provi-
`sional Patent Application Serial No. 60/422,676 filed on Oct.
`31, 2002, which is hereby incorporated by reference in its
`entirety.
`
`BACKGROUND OF THE INVENTION
`
`[0002] The present disclosure relates to stator assemblies
`for electromagnetic machines 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 yoke portion, a tooth
`portion and a coil winding wound about the tooth.
`
`[0003] While the use of distinct and separately wound
`stator segments provides some benefits,
`it potentially
`increases the complexity and costs of manufacturing opera-
`tions. For example, in many segmented stators the stator
`segments are wound individually and one or more manu-
`facturing steps are required to appropriately interconnect all
`the individual stator coils to form the phase windings. In
`such conventional stator 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 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 the need for a secondary retention mecha-
`nism often require a significant capital investment in manu-
`facturing equipment
`to manufacture such machines and
`significant material cost adders to the component costs of
`machines made according to such processes.
`
`In an effort to overcome some of the limitations
`[0004]
`associated with stator assemblies having separately-wound
`stator segments as described above, approaches were devel-
`oped wherein magnetically-interconnected stator segments
`were physically coupled to one another prior to the winding
`operation such that the coils could be formed in an inter-
`connected manner. In known conventional approaches, the
`stator segments were interconnected though the use of
`hinges, sometimes referred to as puzzle lock connections, or
`through the use of thin interconnecting bridges of magneti-
`cally permeable materials. Such interconnecting structure
`often requires relatively complex stator lamination construc-
`tions, which can increase the overall manufacturing costs for
`a machine utilizing such a design. Moreover, the manufac-
`turing steps required to couple the distinct stator segments
`together via the hinge or puzzle lock structure increases the
`cost and complexity of the manufacturing process.
`
`[0005] One limitation of stator assemblies using intercon-
`necting puzzle pieces or bridges is that the stator assembly
`is often fairly inflexible and access to the stator teeth during
`the winding operation is somewhat limited. These limita-
`tions can restrict the extent to which magnetic wires can be
`placed in the stator to form the stator windings or, in other
`words, the “slot fill.”
`
`[0006] 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 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 Japanese
`Patent B-30107085. 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 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 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 necessitates mul-
`tiple manufacturing steps of coupling the winding coils from
`the stator groupings together and structure for coupling the
`multiple stator groupings to form an annular stator. Such
`additional manufacturing steps and structure can signifi-
`cantly increase the costs and manufacturing complexity
`associated with such stators.
`
`[0007] The present disclosure describes several embodi-
`ments of a stator assembly that are designed to address the
`described and other limiting characteristics of conventional
`segmented stator assemblies.
`
`SUMMARY OF THE INVENTION
`
`In accordance with one exemplary embodiment
`[0008]
`constructed in accordance with 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 segments, each stator seg-
`ment defining a yoke portion and a stator tooth, and a
`containment structure configured to position the stator seg-
`ments relative to one another such that the stator segments
`do not physically touch one another and such that no
`magnetic circuit between adjacent
`stator
`segments
`is
`formed.
`
`In accordance with one exemplary process that
`[0009]
`may be performed in accordance 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 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; and deforming the con-
`tainment structure to form an annular stator and to establish
`
`a magnetic circuit between adjacent stator segments.
`
`[0010] Other aspects of the present disclosure will be
`apparent from a review of the disclosure, the figures and the
`claims.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`[0011] The description is presented with reference to the
`accompanying drawings in which:
`
`[0012] FIGS. 1A-1D illustrate portions of an exemplary
`stator assembly constructed in accordance with certain
`teachings of this disclosure prior to the rounding of such a
`stator assembly into an annular form.
`
`[0013] FIG. 2 generally illustrates an exemplary stator
`assembly constructed in accordance with certain teachings
`of this disclosure after it has been rounded into an annular
`form.
`
`Am. Honda v. IV II - IPR2018-006l9
`
`PET_HONDA_1 008-001 1
`
`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1008-0011
`
`

`

`US 2004/0084988 A1
`
`May 6, 2004
`
`[0014] FIG. 3A and 3B generally illustrate certain aspects
`of a hinge assembly that may be used in connection with the
`exemplary embodiment of FIGS. 1A-1C and 2.
`
`[0015] FIG. 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.
`
`[0016] FIGS. 5A-5C generally illustrate an alternate
`embodiment of a stator assembly that may be used in
`connection with the exemplary winding process described in
`connection with FIG. 4.
`
`[0017] FIG. 6 generally illustrates an alternate embodi-
`ment of a hinge structure that may be used in connection
`with a stator assembly as described herein.
`
`[0018] FIG. 7A and 7B generally illustrate alternate
`engagement/locking structures that may be used with a
`stator constructed in accordance with certain teachings
`herein to retain the stator assembly in an annular form.
`
`DESCRIPTION OF EMBODIMENTS
`
`[0019] Turning to the drawings, and in particular to FIGS.
`1A-1D, an exemplary embodiment of an improved seg-
`mented stator assembly 10 constructed in accordance with
`certain teachings of this disclosure illustrated
`
`[0020] Referring to FIGS. 1A-1C, the stator assembly 10
`includes a plurality of discrete, non-interconnected stator
`segments 20 sandwiched between two containment struc-
`tures 30 and 40. In general,
`the stator segments 20 are
`formed form stacks of substantially identical laminations.
`The stator segments 20 are not directly 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 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 another. The contain-
`ment structure is not magnetically conductive. During con-
`struction,
`the independent stator segments 20 are sand-
`wiched between the containment structures 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 form stator coils and phase
`windings. After winding, the stator assembly 10 is rounded
`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. Details of this
`exemplary embodiment are provided below.
`
`[0021] Stator assembly 10 includes twelve stator segments
`20, although alternate embodiments with a different number
`of stator segments 20 are envisioned and possible. The
`construction of each stator segment 20 is similar to the
`construction of the stator segments used in conventional
`segmented stator assemblies. Each stator segment 20 is
`formed form a stack of substantially identical laminations,
`typically stamped from steel. As best reflected in FIGS. 1B
`and 1C, each stack of laminations defines a main yoke
`portion 21 and an extending tooth portion 22 that terminates
`in a “T” shaped portion 23.
`
`[0022] The yoke portion 21 of each stator stack defines an
`engagement projection 24 on one side of the yoke 21, and an
`
`engagement notch 25 on the opposing side of the yoke 21.
`The engagement projection 24 and the engagement notch 25
`are sized such that when adjacent stator segments 20 are
`brought
`together the engagement projection 24 will be
`received in the engagement notch 25. This inhibits relative
`movement of the adjacent stator segments 20 in at least one
`direction. Notably, unlike prior art configurations where
`interlocking puzzle pieces serve to physically connect adja-
`cent stator pieces together,
`the engagement notches and
`projections of the exemplary embodiment do not perform
`that function. Absent some other retaining structure, the
`engagement notches and projections will not physically
`interconnect or hold together adjacent stator segment pieces.
`
`In addition to defining engagement notches and
`[0023]
`projections as described above, the yoke portions 21 of each
`stator segment also define a rear channel 26. Rear channel 26
`sized to receive in a press-fit relationship a portion of the
`containment structures 30 and 40 to help couple the stator
`segments to the containment structures. This is described in
`more detail below.
`
`[0024] The “T” shaped portion 23 of each stator stack 20
`defines an outer section 27 that upon complete assembly will
`be exposed and define a rotor bore and an inner section 28.
`The inner section 28 is configured to help position and retain
`a motor winding coil in a desired position with respect to the
`stator tooth as described in more detail below.
`
`[0025] As described above, stator segments 20 are not
`physically coupled together by hinges, interlocking puzzle
`pieces or other features that are themselves part of the stator
`segments. To the contrary, no direct, stator segment-to-stator
`segment coupling exists between the stator segments 12. The
`two containment structures 20 and 30“sandwich” the stator
`
`segments to form a relatively flexible stator assembly that is
`relatively easy to construct and wind. The stator assembly is
`held together in a form analogous to a “rack-of-ribs” where,
`in an open arrangement as illustrated in FIG. 1A, the solid
`stator segment assemblies 20 do not make contact and are
`not coupled together but are attached by a flexible member.
`The flexible member is the hinges of containment structures
`30 and 40.
`
`[0026] Referring to FIG. 1C, details of one the contain-
`ment structures 30 and 40 are illustrated. In general, each of
`the containment structures 30 and 40 comprises a flexible
`plastic structure that defines various recesses or “pockets” in
`which a stator segment 20 may be positioned and held. The
`pockets are held together by an integral flexible hinges. Slits
`and positioning features (not illustrated in FIGS. 1A-1D) are
`provided to ensure proper positioning of the winding coils.
`Upon final assembly,
`these positioning features will be
`placed about the stator poles.
`[0027] The stator assembly is constructed so as to accom-
`modate three phase windings with each phase winding
`comprising winding coils wound about the teeth of four
`stator segments 20. To accommodate the end-terminals of
`the three phase windings, the upper containment structure 30
`includes six terminal retention features 31a, 31b, 31c, and
`32a, 32b, and 32c that can be used to position and maintain
`the end terminals of three phase windings A, B and C (not
`illustrated in the figures). Each of the terminal retention
`features comprises a slit formed in the containment structure
`and a projecting post around which a portion of the terminal
`end of the phase winding may be wrapped to position the
`terminal end of the winding in a fixed location.
`
`Am. Honda v. IV 11 - IPR2018-006l9
`
`PET_HONDA_1008-0012
`
`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1008-0012
`
`

`

`US 2004/0084988 A1
`
`May 6, 2004
`
`In addition to including the terminal retention
`[0028]
`fixtures, the pockets that form the containment structure 30
`also define slits 33. These slits allow the wires that form the
`
`phase windings to pass from the portion of the containment
`structure 30 that faces the interior of the rotor bore to the
`
`portion of the containment structure 30 that faces the exte-
`rior of the stator assembly. As described in more detail
`below, the slits 33 are positioned to ensure that the wires that
`form the winding coils are positioned in a defined relation-
`ship to the stator assembly and to any exterior shell member
`into which the stator assembly 10 may be positioned.
`
`[0029] Additional details of the pockets that form contain-
`ment members 30 and 40 are depicted in FIGS. 1B and 1C,
`which illustrate corresponding portions of the upper con-
`tainment structure 30 and the lower containment structure 40
`
`for holding a single stator segment 20. Neither the hinges
`that would connect the illustrated portions of the contain-
`ment structures 30 and 40 to adjacent portions nor the
`adjacent portions themselves are depicted in FIGS. 1B and
`1C.
`
`[0030] Referring to FIGS. 1B and 1C it may be noted that
`the containment structure 30 defines a top portion 33 that,
`when placed over a stator segment 20, will generally rest on
`top of the stator segment 20. The containment structure 30
`further defines downwardly extending portions 34 that
`extend downwardly from the top portion 33. The down-
`wardly extending portions 34 are shaped to slide over the
`extending portion 22 of the stator segment. There are two
`downwardly extending portions 34 for each pocket of the
`upper containment structure that will slide over and cover
`the opposing sides of the extending portion 22 of the stator
`segment. As depicted in FIG. 1B1, the ends of the down-
`wardly extending portions 34 define a notched area 35
`having a height H and a thickness T where the portion 24
`changes from a first thickness to a second thickness.
`
`[0031] As further depicted in FIGS. 1B and 1C, the lower
`containment structure 40 defines a bottom portion that will
`rest on the bottom of the stator segment. The pockets of the
`lower containment structure 40 further define upwardly
`extending portions 37 that extend upwardly along the
`extending position of the stator segment 20. As depicted in
`FIG. 1B2 the upwardly extending portions 37 define
`notched areas 38 that are sized to be received in the notch 35
`
`defined by the downwardly extending portions of the upper
`containment structure 40.
`
`[0032] The notched structures of the upper and lower
`containment structures engage one another in a manner
`generally reflected in FIG. 1D such that there is no direct
`path through any opening from the exterior of the insulating
`surface to the metal forming the stator tooth. Specifically, as
`reflected in FIG. 1B, the only path from the exterior of the
`insulator to the metal forming the stator tooth would be
`though the small opening 200, and up the interface between
`the notched surfaces 35 and 38 and across the small opening.
`This engagement of notched surfaces ensures that the wind-
`ing coils are adequately insulated from the stator teeth.
`
`press-fit relationship to help join the containment structures
`30 and 40 onto the stator segments 20 and to prevent relative
`movement between the stator segments 20 and the upper and
`lower containment structures 30 and 40.
`
`[0034] As FIGS. 1A-1C illustrate, when the containment
`structures 30 and 40 are placed over a group of stator
`segments 20 such that multiple stator segments are sand-
`wiched between the containment structures 30 and 40,
`portions of the containment structures 30 and 40 will sur-
`round and encase the extending portions 22 of the stator
`segments 20. Additionally, containment structures 30 and 40
`will provide an insulating barrier between the region interior
`of the T-shaped portion of the stator segments 20 and the
`T-shaped end of the stator segments and between the region
`interior of the T-shaped end of the stator segments and the
`portion of the yokes of the stator segments that will face
`inwardly towards the stator bore. When positioned about the
`stator, the containment structures 30 and 40 thus insulate any
`winding coil wound about the stator teeth of the stator
`segments 20 from the metal forming the stator segments. As
`reflected best in FIG. 1A, a portion 27 each stator tooth is
`not covered by any portion of the containment structures and
`such exposed section will extend into the interior rotor bore
`when the stator assembly is rounded into an annular form.
`
`[0035] Additional details of the upper and lower contain-
`ment structures 30 and 40 are illustrated in FIG. 3A and
`
`FIG. 3B, which illustrate a top down view of a portion of an
`exemplary upper containment structure 30. As illustrated,
`the containment structure 30 defines, for each pocket, an end
`portion 300 that fits over the T-shaped end of the stator
`assembly 20. While not illustrated in FIGS. 3A and 3B, a
`similarly shaped portion exists on the lower containment
`structure 40. The end portion 300 is ramped to define a
`surface that will tend to cause any winding coil wound about
`the stator teeth to be pressed into or retained within the slot
`that will exit between adjacent stator teeth.
`
`[0036] FIGS. 3A and 3B further illustrate details of
`exemplary embodiments of hinge 42 that connects the
`adjacent pockets of the upper containment member 30.
`Similar hinges are found on the lower containment member
`40. As illustrated, the hinge 42 comprises a small region of
`thin plastic that couples adjacent pockets of the containment
`structures together. The hinge element 42 is a “living hinge”
`in that it is relatively freely bendable in both directions.
`Moreover, the point of the hinge at which the bending occurs
`is substantially at the outer periphery of the stator assembly
`when the stator assembly is rounded into an annular form.
`FIG. 3A illustrates a hinge 42 in a closed configuration and
`FIG. 3B illustrates an exemplary hinge 42 in a generally
`open configuration. The pockets of FIG. 3B are not pockets
`associated with the terminals of the phase windings and, as
`such, no terminal retention features are illustrated in the
`figure. The slits 33 for allowing passage of the wire forming
`the winding coils from the interior of the stator assembly to
`the exterior of the stator assembly are illustrated in FIGS.
`3A and 3B.
`
`[0033] The upper and lower containment structures 30 and
`40 further define extending flanges at the end of the struc-
`tures that fit near the T-shaped ends of the stator assemblies.
`The containment structures 30 and 40 further define upper
`and lower projections 39a and 39b that are configured to fit
`into the channels 26 formed in the stator segments in a
`
`[0037] After the stator core segments 10 are positioned
`within the containment structures 30 and 40 to form a
`
`flexible strip assembly as depicted in FIG. 1A, winding coils
`are wound about the stator teeth so as to form a plurality of
`phase windings. In the example of FIGS. 1A-1D, winding
`coils may be positioned to provide three phase windings,
`
`Am. Honda v. IV II - IPR2018-006l9
`
`PET_HONDA_1008-0013
`
`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1008-0013
`
`

`

`US 2004/0084988 A1
`
`May 6, 2004
`
`with each phase winding including four winding coils. Other
`constructions are possible with the phase winding including
`fewer or greater numbers of winding coils.
`
`[0038] The phase windings are formed by the following
`process. First, beginning of one phase winding is inserted
`into a terminal retention feature. Then, a winding coil is
`formed about the appropriate stator tooth. The wire is run out
`towards the back of the containment structure 30 through a
`slot 33, through the back of the portion of the containment
`structure associated with the next two adjacent stator teeth,
`bringing the wire in towards the tooth of the third adjacent
`stator teeth through a slit 33 in the relevant portion of the
`containment structure. This process is repeated until all the
`winding coils for the phase winding are formed.
`
`[0039] The winding procedure described above can be
`accomplished in a variety of ways. In accordance with one
`exemplary winding process, a needle winding process is
`used wherein the coils that form the phase winding may be
`wound individually. In an alternate process, the coils that
`form the phase windings are wound simultaneously with one
`needle being provided for each phase windings.
`
`[0040] One of the benefits of the “living” hinge illustrated
`above is that the stator assembly 10, prior to being rounded
`into an annular form, can be fully opened to allow greater
`access to the slot area for winding, thus allowing a greater
`slot fill and allowing for enhanced precision winding tech-
`niques. The ability of the described embodiment to be fully
`open as described above allows the stator assembly to be fly
`wound at speeds faster than those that exist for conventional
`stator winding techniques and potentially enables slot fills
`greater than previously available.
`
`[0041] FIGS. 3A and 3B also illustrate yet another pre-
`ferred embodiment of the present disclosure, where web 43
`and shields 44 are added to create a clearance between the
`coils and the stator stack when rounded into annular form.
`
`Web 43 and shields 44 run the entire length of each segment
`and are preferably made of plastic. As shown in FIGS. 3A
`and 3B, web 43 is designed in a manner so as to provide the
`flexibility to perform the winding process described herein-
`above. Two shields 44 are provided on opposite sides of each
`containment structure to ensure that the winding coils are
`adequately insulated from each stator tooth.
`
`[0042] FIG. 4 generally illustrates a stator assembly 10
`formed as described above in connection with FIGS. 1A-1D.
`
`In the illustrated stator assembly, there are to be three phase
`windings, A, B and C. In FIG. 4, each tooth of the stator is
`identified with a label identifying the phase winding to
`which it corresponds and the polarity of the winding to be
`placed about the stator tooth. As those of ordinary skill in the
`art will appreciate, by winding the winding coil about the
`stator tooth in a first direction one is able to achieve an
`
`electromagnet of a first polarity when the winding is ener-
`gized in a first direction. By winding the coil in the opposite
`direction, when the winding coil is energized in the same
`direction,
`it is possible to establish an electromagnet of
`opposing polarity. Thus, FIG. 4 identifies each stator tooth
`as being associated with a phase winding A, B or C and a
`particular polarity +or —. The winding pattern of FIG. 4 is
`exemplary only and other winding patterns can be used
`without departing from the teachings of this disclosure.
`
`the
`[0043] Referring to FIG. 4 it may be noted that
`winding operation is performed through the use of a tooling
`
`element 400 that engages features on the stator assembly 10
`so as to move the stator assembly 10 during the winding
`operation. The tooling element 400 moves the stator assem-
`bly during operation such that, at various times, the stator
`assembly is positioned to expose differing stator teeth to
`enable easy and fast precision fly winding. For example, in
`FIG. 4, the stator assembly is positioned such that a set of
`stator teeth A-, B- and C- are exposed. Needle or fly winding
`techniques may be used to wind one or more of the exposed
`stator teeth. In this manner the stator assembly may be
`rapidly and quickly wound.
`
`[0044] Regardless of whether fly or needle winding tech-
`niques are employed, and regardless of whether the stator
`assembly is wound in a configuration as illustrated in FIG.
`1A or in the open configuration of FIG. 4, the exemplary
`stator assembly disclosed herein is constructed such that the
`phase windings can be placed in the stator assembly with no
`more than three starts and three finishes. For example in a
`winding operation where each stator tooth is individually
`wound, a winding operation could begin with the stator
`assembly positioned such that a winding coil is positioned
`about a first stator tooth (labeled A+402 in FIG. 4). The
`winding apparatus could then proceed to wind the next tooth
`corresponding to the phase A winding (labeled A—402 in
`FIG. 4) without having to stop the winding process or cut
`the wire forming the phase winding. The process could
`continue until all of the teeth corresponding the phase
`winding were wound. After the phase A winding was com-
`pleted,
`the next phase winding could be wound on the
`machine.
`
`[0045] The winding approach and processes described
`above allowing for an “open” winding of the stator assembly
`10 as depicted in FIG. 4 can be beneficially applied to stator
`assemblies having alternate constructions, such as stator
`assemblies where the stator segments are interconnected to
`one another directly by, for example, interlocking puzzle
`pieces.
`
`[0046] FIGS. 5A-5C generally illustrate a stator assembly
`500 that is formed from stator segments 501 where the stator
`segments 501 are directly coupled together by interlocking
`puzzle pieces. The construction of the stator segments 501
`and the insulators 501 used with such segments is such that
`the stator assembly may be fully opened to allow complete
`access to the winding. FIGS. 5B1 and 5B2 generally illus-
`trate a stator segment 501 of the type used in the embodi-
`ment of FIG. 5A. The stator segment defines a yoke 502 and
`an extending tooth portion 503. The yoke 502 further defines
`a projecting element 504 and a receptive element 505, where
`the projecting element 504 is sized to fit into the receptive
`element 505 of a neighboring stator segment to create a
`chain-like stator assembly. The projecting element 504
`defines upper and lower recesses and the receptive element
`defines upper and lower extensions. The upper and lower
`recesses are sized so as to receive the upper and lower
`extensions of an adjacent stator segment. This arrangement
`of interfering recesses and projections allows for the stator
`assembly to be opened for full and fast winding as described
`above.
`
`[0047] FIGS. SCI and 5C2 generally illustrate the form of
`insulating elements that may be positioned about the stator
`segments of FIGS. 5B1 and 5B2 to produce the stator
`assembly of FIG. 5A. In general, the insulating elements
`
`Am. Honda v. IV II - IPR2018-006l9
`
`PET_HONDA_1008-0014
`
`Am. Honda v. IV II - IPR2018-00619
`PET_HONDA_1008-0014
`
`

`

`US 2004/0084988 A1
`
`May 6, 2004
`
`comprise plastic elements that fit over the individual stator
`segments to insulate the winding coil to be placed about the
`stator tooth from the metal that forms the stator tooth. Each
`
`insulating element has an upper component 510 and a lower
`component 512, where each of the upper and lower com-
`ponents defines a top (or bottom) section that forms an
`insulating barrier between the top and bottom of the stator
`tooth and the winding coil and a downward (or upward)
`extension 514, 516 that serves to insulate the winding coil
`from the portion of the yoke that faces the interior bore of
`the stator. Other insulating materials (not illustrated) may be
`used to provide insulation between the sides of the st