Electric motor stator

Abstract

Devices and methods are provided for a motor stator. One embodiment for a stator includes a frame for stator windings that includes a hub, spacing members, a rim and posts for receiving and positioning windings of a stator coil. A thermoset material is supplied to the stator to encapsulate the stator.

1 . A method of forming a frame for stator windings, comprising: 
 providing a first winding guide and a second winding guide on a hub in a radially staggered configuration;    providing a spacing member that connects the hub to a rim; and    providing a post on the rim.    
   
   
       2 . The method of  claim 1 , where providing a first winding guide and a second winding guide includes providing walls that define a curved surface having a first end and a second end for each of the first winding guide and the second winding guide, and positioning the first and second end of adjacent first winding guides between the first and second end of the second winding guide.  
   
   
       3 . The method of  claim 2 , including providing a ledge that extends from both the first winding guide to the first and second end of adjacent second winding guides, and the second winding guide to the first and second end of adjacent first winding guides.  
   
   
       4 . The method of  claim 2 , where providing the spacing member includes positioning the spacing member to extend radially from a position adjacent the first end and the second end of adjacent first winding guides and adjacent second winding guides.  
   
   
       5 . The method of  claim 2 , where the curved surface is concave having a bottom relative the first end and the second end, where the first end and second end of the first and second winding guides are further away from a center axis of the hub than the bottom of the curved surface.  
   
   
       6 . The method according to  claim 1 , where forming the frame includes coupling the rim to the spacing member, where the rim is annularly positioned relative the hub.  
   
   
       7 . The method according to  claim 1 , including providing a support ledge on the rim, where the support ledge has two or more sections each with surfaces defining wire guide channels that encircle the hub.  
   
   
       8 . The method of  claim 1 , where posts extend perpendicularly from the rim.  
   
   
       9 . A method of forming a stator, comprising: 
 forming a frame that includes: 
 a hub having a first winding guide and a second winding guide that are radially staggered relative each other by a predetermined angle;  
 a rim annularly positioned relative the hub;  
 posts on the rim; and  
   providing windings of conductive wire around at least a portion of the posts and adjacent the first winding guide and the second winding guide of the hub forming coils of an alternating current motor.    
   
   
       10 . The method of  claim 9 , where forming the frame includes positioning the posts on the rim where a predetermined portion of each of the posts extends above and below the rim receiving the windings of conductive wire.  
   
   
       11 . The method of  claim 10 , where providing windings of conductive wire includes extending windings of conductive wire around adjacent posts above the rim and by the first winding guide; and 
 extending windings of conductive wire around adjacent posts below the rim and by the second winding guide to form coils for the alternating current motor.    
   
   
       12 . The method of  claim 11 , where a first portion of the coils share one of a first common radial plane and a second common radial plane, and a second portion of the coils share a third common radial plane that is different than the first and second common radial planes.  
   
   
       13 . The method of  claim 9 , where forming coils includes partially containing a start lead segment and a finish lead segment within the rim.  
   
   
       14 . The method of  claim 9 , where forming the stator further includes encapsulating the hub, the rim, the posts and windings of conductive wire with a housing.  
   
   
       15 . The method of  claim 9 , where forming the frame includes providing spacing members that connect the hub to the rim.  
   
   
       16 . A method of forming an electric motor, comprising: 
 providing a stator that includes: 
 a hub including a rotor interface, a first winding guide and a second winding guide, the first and second winding guides positioned opposite the rotor interface and radially staggered relative each other by a predetermined angle;  
 a rim annularly positioned relative the hub;  
 posts positioned on the rim;  
 windings of conductive wire around at least a portion of the posts and adjacent the first winding guide and the second winding guide of the hub to form coils of the electric motor; and  
 connector terminals coupled to the windings for providing a potential through the coils to operate the electric motor;  
   fixing the stator within an interior space of a motor enclosure; and    positioning a rotor adjacent the stator and rotatably coupled within the interior space of the motor enclosure.    
   
   
       17 . The method of  claim 16 , where providing the stator includes providing a support ledge of the rim, where the support ledge has two or more sections each having surfaces defining wire guide channels that encircle the hub, and where each of the coils includes a start lead segment and a finish lead segment at least partially contained within the wire guide channels.  
   
   
       18 . The method of  claim 17 , where providing the stator further includes coupling the start lead segment and the finish lead segment for each of the coils to the connector terminals for operating the electric motor in one of a single phase configuration and polyphase configuration.  
   
   
       19 . The method of  claim 16 , where providing the stator includes over-molding the hub, the rim, the posts and windings of conductive wire, where the connector terminals extend from the over-molding.  
   
   
       20 . The method of  claim 19 , where the housing is a thermoset material formed from a liquid resin thermoset precursor that is selected from an unsaturated polyester, a polyurethane, an epoxy, a phenolic, a silicone, an alkyd, an allylic, a vinyl ester, a furan, a polyimide, a cyanate ester, a bismaleimide, a polybutadiene, and a polyetheramide.