阅读说明：本技术 用于冷却电动机的装置及其制造方法 (For cooling down the device and its manufacturing method of motor ) 是由 A·M·科波拉 A·法特米 D·F·拉尔 于 2019-05-08 设计创作，主要内容包括：本文提供了一种用于电动机的定子。该定子可包括定子主体,该定子主体包括多个层压件、多个导线绕组和由该导线绕组形成的绕组端匝。该定子还可包括围绕定子主体的外表面的至少一部分设置的聚合物复合材料壳体和用于加热和/或冷却定子的限定在聚合物复合材料壳体中的多个通道。本文还提供了制造定子的方法。(There is provided herein a kind of stators for motor.The stator may include stator body, which includes multiple laminates, multiple wire windings and the winding end turn formed by the wire winding.The stator may also include the polymer composite shell of at least part setting around the outer surface of stator body and the multiple channels being limited in polymer composite shell for heating and/or cooling stator.The method of manufacture stator is also provided herein.)

1. a kind of stator for motor, includes:

Multiple laminates, each laminate includes multiple slots, wherein the multiple slot limits first end face and second jointly End face；

Multiple wire windings are arranged in the multiple slot；

A winding end turn more than first, is formed by each wire winding adjacent with the first end face；

A winding end turn more than second, is formed by each wire winding adjacent with the second end face, wherein more than described first Winding end turn has the first periphery, and a winding end turn more than described second has the second periphery；

First polymer composite material casing, around at least one of first periphery of more than described first a winding end turns Set up separately and sets；

Second polymer composite material casing, around at least one of second periphery of more than described second a winding end turns Set up separately and set, wherein the first polymer composite material casing and the second polymer composite material casing respectively contain polymerization Object；With

Multiple channels are used to receive for heating and/or cooling a winding end turn more than described first and/or more than second described The fluid of winding end turn,

Wherein the multiple channel is limited in following one or more:

(i) the first polymer composite material casing；

(ii) the second polymer composite material casing；

(iii) region more than described first between each wire winding of a winding end turn；With

(iv) region more than described second between each wire winding of a winding end turn.

2. stator according to claim 1, wherein described poly- in first and second polymer composite shell It closes object and respectively contains thermoplastic polymer or thermosetting polymer.

3. stator according to claim 1, wherein first and second polymer composite shell respectively also includes More reinforcing fibers, wherein the more reinforcing fibers are selected from by carbon fiber, glass fibre, aramid fibre, poly- second Alkene fiber, organic fiber, metallic fiber, ceramic fibre, basalt fibre, quartz fibre, graphite fibre, nanofiber, boron are fine The continuous fiber of the group of dimension and combinations thereof composition.

4. stator according to claim 1, wherein the multiple channel includes shell, the shell includes metal, polymerization Object, polymer composites, ceramics or combinations thereof.

5. stator according to claim 1, wherein the multiple channel is limited to the first polymer composite shell In body and the second polymer composite material casing, and it is wherein described more in the first polymer composite material casing A channel is circumferentially extended around more than described first a winding end turns, and described more in the second polymer composite material casing A channel is around more than described second a winding end turn circumferentially extendings.

6. stator according to claim 5, wherein the multiple channel in the first polymer composite material casing It is interconnected amongst one another, and the multiple channel in the second polymer composite material casing is interconnected amongst one another.

7. stator according to claim 5, wherein the multiple channel in the first polymer composite material casing First entrance and first outlet are separately included, and the multiple channel in the second polymer composite material casing is wrapped respectively Containing second entrance and second outlet.

8. stator according to claim 5, wherein the multiple channel in the first polymer composite material casing With the multiple passage in the second polymer composite material casing.

9. stator according to claim 1, wherein the multiple channel is limited to the first polymer composite shell In body and the second polymer composite material casing, and it is wherein described more in the first polymer composite material casing Radially prolong between each wire winding end turn of winding end turn a more than described first and between each wire winding in a channel It stretches, and the multiple channel in the second polymer composite material casing is each in winding end turn a more than described second It is radially extended between wire winding end turn and between each wire winding.

10. stator according to claim 9, wherein the multiple channel in the first polymer composite material casing It is interconnected amongst one another by the first manifold passage, and the multiple channel in the second polymer composite material casing passes through second Manifold is interconnected amongst one another.

11. stator according to claim 1, wherein the multiple channel is by formed below:

Channel precursor material comprising expendable material is applied on the stator to form intermediate stator component；

The intermediate stator component is put into mold；

The polymer precursor is introduced into the mold；

Solidify the polymer precursor to form the first polymer composite material casing and the second polymer composite wood Material shell body；With

The expendable material is removed to form multiple channels.

Summary of the invention

This part provides the overview of the disclosure, rather than the comprehensive disclosure of its full scope or its all feature.

In some aspects, the present invention provides a kind of stators for motor comprising multiple laminates, each lamination Part includes multiple slots, wherein multiple slot limits first end face and second end face jointly.Stator further includes being arranged in multiple slots Multiple wire windings, more than first a winding end turns for being formed by each wire winding adjacent with first end face, and by with More than second a winding end turns that the adjacent each wire winding of second end face is formed.A winding end turn more than first has outside first Week, and a winding end turn more than second has the second periphery.First polymer composite material casing can surround more than first a windings At least part of first periphery of end turn is arranged, and second polymer composite material casing can surround more than second a winding terminals At least part of second periphery of circle is arranged.Wherein first polymer composite material casing and second polymer composite shell Body respectively includes polymer.Stator further includes multiple channels, for receiving for heating and/or cooling a winding end turn more than first With the fluid of more than second a winding end turns.Multiple channels can be limited to following one or more: (i) first polymer composite wood Material shell body；(ii) second polymer composite material casing；(iii) area more than first between each wire winding of a winding end turn Domain；Region between each wire winding of (iv) more than second a winding end turn.

Polymer in first and second polymer composite shells respectively may include thermoplastic polymer or thermosetting property Polymer.

First and second polymer composite shells each may also include more reinforcing fibers.The more reinforcing fibers can Be selected from carbon fiber, glass fibre, aramid fibre, polyethylene fibre, organic fiber, metallic fiber, ceramic fibre, The continuous fiber of basalt fibre, quartz fibre, graphite fibre, nanofiber, boron fibre and combinations thereof.

Multiple channels may include shell, which includes metal, polymer, polymer composites, ceramics or combinations thereof.

Multiple channels can be limited in first polymer composite material casing and second polymer composite material casing.The Channel in one polymer composite shell can be around more than first a winding end turn circumferentially extendings, and second polymer is compound Multiple channels in material housing can be around more than second a winding end turn circumferentially extendings.

Multiple channels in first polymer composite material casing can be interconnected amongst one another, and second polymer composite shell Multiple channels in body can be interconnected amongst one another.

Multiple channels in first polymer composite material casing respectively include first entrance and first outlet, the second polymerization Multiple channels in object composite material casing respectively include second entrance and second outlet.

Multiple channels in first polymer composite material casing can with it is more in second polymer composite material casing A passage.

Multiple channels can be limited in first polymer composite material casing and second polymer composite material casing in. Multiple channels in first polymer composite material casing can between each winding end turn in winding end turn a more than first with And radially extended between each wire winding, and multiple channels in second polymer composite material casing can more than second around It is radially extended between each winding end turn in group end turn and between each wire winding.

Multiple channels in first polymer composite material casing can be interconnected amongst one another by the first manifold passage, and second is poly- Multiple channels in compound composite material shell can be interconnected amongst one another by the second manifold passage.

Intermediate stator component can be formed by following: it is fixed that the channel precursor material including expendable material is applied to Son, by intermediate stator component place in a mold, polymer precursor is introduced into mold, curable polymer precursor is to form first Polymer composite shell and second polymer composite material casing, and expendable material is removed to form multiple channels.

In other respects, there is the method for the stator in multiple channels present disclose provides a kind of manufacture.This method includes will Channel precursor material including expendable material is applied to stator to form intermediate stator component.Stator includes multiple laminates, often A laminate includes multiple slots, and plurality of slot limits first end face and second end face jointly.Stator further includes being arranged multiple Multiple wire windings in slot, more than the first a winding end turns formed by each wire winding adjacent with first end face, and More than the second a winding end turns formed by each wire winding adjacent with second end face.A winding end turn more than first has first Periphery, and a winding end turn more than second has the second periphery.This method may also include by intermediate stator component place in a mold, Polymer precursor is introduced into mold and curable polymer precursor is to form solid polymer stator module, the stator module First polymer composite material casing including at least part setting around the first outer periphery of more than first a winding end turns With the second polymer composite material casing of at least part setting around the second periphery of more than second a winding end turns.First Polymer composite shell and second polymer composite material casing respectively include polymer.This method further includes that removal is sacrificed Material be formed in be limited to one of the following or it is multiple in multiple channels: (i) first polymer composite material casing； (ii) second polymer composite material casing；(iii) region more than first between each wire winding of a winding end turn；(iv) Region more than second between each wire winding of a winding end turn.

Polymer precursor may include thermoplastic polymer or thermosetting polymer.

Apply channel precursor material may include circumferentially apply channel precursor material around more than first a winding end turns, and Circumferentially apply channel precursor material around more than second a winding end turns.

Applying channel precursor material may include each conducting wire that channel precursor material is applied to a winding end turn more than first At least part region between winding and more than second a winding end turns.

Apply channel precursor material may include between each winding end turn in winding end turn a more than first radially Apply channel precursor material, and radially applies channel precursor between each winding end turn in winding end turn a more than second Material.

Expendable material may include being able to carry out one of fusing, evaporation, detonation and solubilising or a variety of materials.

Channel precursor material may include the shell containing expendable material.The shell may include that metal, polymer, polymer are multiple Condensation material, ceramics or combinations thereof, and expendable material may include be able to carry out one of fusing, evaporation, detonation and solubilising or A variety of gas or material.Shell can be retained after removing expendable material.

This method, which may further include, removes solid polymer stator module from mold and before removing expendable material Solid polymer stator module is placed in stator case or further comprises that intermediate module is placed in stator case And it will be in the stator case of intermediate module placement in a mold.

In other respects, the present invention provides a kind of stator for motor, including multiple laminates, each laminate packet Multiple slots are included, plurality of slot limits first end face and second end face jointly, and plurality of laminate has outer surface.It is fixed Son further includes the multiple wire windings being arranged in multiple slots, formed by each wire winding adjacent with first end face first Multiple winding end turns, and more than the second a winding end turns formed by each wire winding adjacent with second end face.More than first A winding end turn has the first periphery, and a winding end turn more than second has the second periphery.Stator further includes polymer composite Material shell body and multiple channels for receiving the fluid for heating and/or cooling stator, plurality of channel is limited to polymerization In object composite material casing.Polymeric shells can be set around following: at least part of the outer surface of (i) laminate； (ii) at least part of the first periphery of a winding end turn more than first；Second periphery of (iii) more than second a winding end turn At least part.Polymer composite shell may include polymer.

Polymer in polymer composite shell may include thermoplastic polymer or thermosetting polymer.

Each polymer composite shell may also include more reinforcing fibers.The more reinforcing fibers can be selected from carbon Fiber, glass fibre, aramid fibre, polyethylene fibre, organic fiber, metallic fiber, ceramic fibre, basalt are fine The continuous fiber of dimension, quartz fibre, graphite fibre, nanofiber, boron fibre and combinations thereof.

Multiple channels may include shell, which includes metal, polymer, polymer composites, ceramics or combinations thereof.

Multiple channels in polymer composite shell can surround following circumferentially extending: the outer surface of (i) laminate； (ii) a winding end turn more than first；(iii) a winding end turn more than second.

It multiple channels can be interconnected amongst one another.

Multiple channels may include third entrance and third outlet.

Can by will include that the channel precursor material of expendable material is applied to stator to form intermediate stator component, will in Between stator module place in a mold, polymer precursor is introduced into mold, curable polymer forms multiple channels.It is formed poly- The precursor of compound composite material shell, and expendable material is removed to form multiple channels.

In other respects, there is the method for the stator in multiple channels present disclose provides a kind of manufacture.This method includes will Channel precursor material including expendable material is applied to stator to form intermediate stator component.Stator includes multiple laminates, often A laminate includes multiple slots, and plurality of slot is first end face and second end face jointly, and plurality of laminate has Outer surface.Stator further includes the multiple wire windings being arranged in multiple slots, by each wire winding adjacent with first end face More than the first a winding end turns formed, and more than the second a winding end turns formed by each first end face.With second end face phase Adjacent winding.A winding end turn more than first has the first periphery, and a winding end turn more than second has the second periphery.This method is also wrapped Include by intermediate stator component place in a mold, polymer precursor is introduced into mold, curable polymer precursor with formed including The solid polymer stator module of polymer composite shell, and expendable material is removed to form multiple channels of restriction poly- In compound composite material shell.Polymer composite shell can be set: at least one of the outer surface of (i) laminate Point；(ii) at least part of the first periphery of a winding end turn more than first；(iii) the second periphery of a winding end turn more than second At least part.Polymer composite shell may include polymer.

Applying channel precursor material may include circumferentially applying channel precursor material: (i) lamination around following manner Outer surface；(ii) a winding end turn more than first；(iii) a winding end turn more than second.

Expendable material may include that can melt, evaporation, one of detonation and solubilising or a variety of materials.

Channel precursor material may include the shell containing expendable material.The shell may include that metal, polymer, polymer are multiple Condensation material, ceramics or combinations thereof, and expendable material may include can melt, evaporate, one of detonation and solubilising or a variety of Gas or material.Shell can be retained after removing expendable material.

This method, which may also include, is applied to intermediate stator component for insertion piece.

In other respects, present disclose provides a kind of stator for motor, including stator body, the stator body packets Include multiple laminates, multiple wire windings, and the multiple winding end turns formed by each wire winding.Stator further includes surrounding The outer surface of stator body at least part setting polymer composite shell, and for receive for heat and/ Or multiple channels of the fluid of cooling stator, plurality of channel is limited in polymer composite shell.The polymer is multiple Condensation material shell includes polymer.

Polymer in polymer composite shell may include thermoplastic polymer or thermosetting polymer.

Polymer composite shell may also include more reinforcing fibers.The more reinforcing fibers can be selected from carbon fiber Dimension, glass fibre, aramid fibre, polyethylene fibre, organic fiber, metallic fiber, ceramic fibre, basalt fibre, The continuous fiber of quartz fibre, graphite fibre, nanofiber, boron fibre and combinations thereof.

Channel may include shell, which includes metal, polymer, polymer composites, ceramics or combinations thereof.

By by include expendable material channel precursor material be applied to stator body with formed intermediate stator component, will in Between stator module place in a mold, polymer precursor is introduced into mold, curable polymer precursor it is compound to form polymer Material housing, and expendable material is removed to form multiple channels.

According to description provided herein, other suitable application areas be will become obvious.Description and tool in the content of present invention The purpose that body example is merely to illustrate, it is no intended to limit the scope of the present disclosure.

Detailed description of the invention

Attached drawing described herein is only used for the illustrative purpose of selected embodiment, rather than all possible embodiment, And it is not intended to be limited to the scope of the present disclosure.

Fig. 1 is according to one aspect of the disclosure including polymer composite shell and channel defined therein The perspective view of stator module.

Fig. 2 is the perspective cross-sectional view of the stator module of Fig. 1.

Fig. 3 A is the cross-sectional view of single laminate according to one aspect of the disclosure.

Fig. 3 B is the perspective view of multiple laminates according to one aspect of the disclosure.

Fig. 4 A is the perspective view according to the stator module including concentratred winding configuration of disclosure another aspect.

Fig. 4 B is flattening cross-sectional view of the stator module of Fig. 4 A on the plane perpendicular to the rotation axis of component.

Fig. 4 C is the flattening cross-sectional view of B-B along Fig. 4 B according to one aspect of the disclosure.

Fig. 4 D is the flattening cross-sectional view of B-B along Fig. 4 B according to disclosure another aspect.

Fig. 5 A is the perspective view according to a part of the stator module including bar shaped winding end turn of disclosure another aspect.

Fig. 5 B is the flattening cross-sectional view of C-C along the stator module of Fig. 5 A.

Fig. 5 C is the flattening cross section of C-C along the stator module including polymer composite shell and channel of Fig. 5 A Figure.

Fig. 6 be according to disclosure another aspect include determining for polymer composite shell and channel defined therein The perspective graph of sub-component.

Fig. 7 is the flattening side cross-sectional view of the stator module of Fig. 6.

Fig. 8 be include shell channel cross-sectional view.

Fig. 9 A-9D shows the method for manufacture stator module according to one aspect of the disclosure.Fig. 9 A is intermediate stator The flattening top view of component, it illustrates according to one aspect of the disclosure channel material is applied to winding end turn.Fig. 9 B It is the flattening cross-sectional view of the intermediate stator component of Fig. 9 A.Fig. 9 C is the flattening cross-sectional view of the stator body of Fig. 9 A, is shown The formation of solid polymer stator module according to one aspect of the disclosure.Fig. 9 D is that the flattening of the stator body of Fig. 9 A is horizontal Sectional view, it illustrates the formation in the channel in the first and second polymer composite shells.

Figure 10 A-10C shows the method for the manufacture stator module according to disclosure another aspect.Figure 10 A is along Fig. 4 A Line A-A stator module 400 flattening cross-sectional view, it illustrates according to the application expendable material of disclosure another aspect with Form intermediate stator component.Figure 10 B is along the flattening cross-sectional view of the stator module 400 of the line A-A of Fig. 4 A, and it illustrates roots According to the formation of the solid polymer stator module of disclosure another aspect.Figure 10 C is the stator module of the line A-A in Fig. 4 A 400 flattening cross-sectional view, it illustrates the formation in the channel in first polymer composite material casing.

Figure 11 A-11C shows the method for the manufacture stator module according to disclosure another aspect.Figure 11 A is along Fig. 5 A Line C-C stator module 500 flattening cross-sectional view, it illustrates according to the application expendable material of disclosure another aspect with Form intermediate stator component.Figure 11 B is along the flattening cross-sectional view of the stator module 500 of the line C-C of Fig. 5 A, and it illustrates roots According to the formation of the solid polymer stator module of disclosure another aspect.Figure 11 C is the stator module 500 of the line C-C along Fig. 5 A Flattening cross-sectional view, it illustrates the formation in the channel in first polymer composite material casing.

Figure 12 A-12F shows the method for the manufacture stator module according to disclosure another aspect.Figure 12 A is according to this public affairs The side view of the stator module for the one aspect opened, it illustrates the application expendable materials according to disclosure another aspect to be formed Intermediate stator component.Figure 12 B is the side view according to the substitution intermediate stator component of disclosure another aspect.Figure 12 C is basis The side view of the alternative intermediate stator component of disclosure another aspect.Figure 12 D is poly- according to the solid of disclosure another aspect Close the side view of object stator module.Figure 12 E is the side according to the alternative solid polymer stator module of disclosure another aspect View.Figure 12 F is the side view for showing the formation in channel in polymer composite shell.

Figure 13 A is the cross-sectional view of expendable material according to an aspect of the present invention.

Figure 13 B is the cross-sectional view of expendable material according to another aspect of the present invention.

Figure 14 is the alternative arrangements of the intermediate stator component from Fig. 9 B.

Figure 15 is the alternative arrangements of the solid polymer stator module from Fig. 9 C.

Figure 16 is electric motor assembly according to one aspect of the disclosure.

Each appended drawing reference indicates corresponding component in several views of attached drawing.

Specific embodiment

Exemplary embodiment is described more fully with reference to the drawings.

Exemplary embodiment is provided so that the disclosure is comprehensive, and the scope of the present invention will be fully conveyed to affiliated neck The technical staff in domain.Many details, such as concrete composition, the example of components, apparatus, and method are proposed, with offer pair The thorough understanding of the embodiment of present disclosure.It will be apparent to one skilled in the art that not needing using certain detail Section, can be embodied in many different forms exemplary embodiment, and both be not necessarily to be construed as the model of the limitation disclosure It encloses.In some exemplary embodiments, well-known process, well-known device structure and many institute's weeks are not described in The technology known.

Terms used herein are only used for the purpose of description certain exemplary embodiments, rather than restrictive.As herein Used, singular " one ", "one" and "the" also may include plural form, unless the context is clearly stated. Term "comprising", " containing ", " comprising " and " having " are inclusives, thus specify the feature, element, composition, step, Integer, operation and/or the presence of component, but do not preclude the presence or addition of other one or more features, integer, step, operation, Component, assembly unit and/or its group.Although open-ended term "comprising" is interpreted as describing and requiring various realities as described herein Apply the non-limiting term of example, but in some aspects, the term be alternatively interpreted as more being restrictive with restrictive term, Such as " by ... form " or " substantially by ... form ".Therefore, for reference composition, material, component, element, Feature, integer, operation and/or processing step any given embodiment, the disclosure also specifically includes the combination quoted by these The embodiment that object, material, component, element, feature, integer, operation and/or processing step are formed or be substantially made of them. " by ... form " in the case where, alternate embodiment excludes any other composition, material, component, element, spy Sign, integer, operation and/or processing step, and in the case where " substantially by ... form ", any other composition, Material, component, element, feature, integer, operation and/or the processing step for substantially influencing basic and novel features are not included in In such embodiment, but any composition, material, component, element, feature, integer, operation and/or will not substantially it influence The processing step of basic and novel features may include in embodiment.

Except order of performance is non-specifically identified as, otherwise any method and step described herein, process and operation should not be solved It is interpreted as necessarily requiring them the particular order to discuss or illustrate to execute.It should also be understood that unless otherwise stated, can be used In addition or substitution the step of.

When component, element or layer be referred to as " on ", " being joined to ", " being connected to ", " being attached to " or " being coupled to " it is another When element or layer, it can directly on other component, element or layer or can and they engage, connection, attachment or coupling, Or may exist intermediary element or layer.It is referred to as " directly connecting " on the contrary, working as an element, " directly engaging ", " is directly connected to To ", " being directly attached to " or " being directly coupled to " another element or when layer, intermediary element or layer may be not present.For retouching Other words for stating relationship between element should explain in a similar way (for example, " ... between " with " directly exist ... Between ", " adjacent " and " direct neighbor " etc.).As it is used herein, term "and/or" includes listed by one or more correlations Any and all combinations of project.

Although term first, second, third, etc. can be used herein to describe various steps, component, assembly unit, region, layer And/or part, but unless otherwise stated, these steps, component, assembly unit, regions, layers, and/or portions should not be by these The limitation of clause.These terms can only be used to a step, component, assembly unit, region, layer or part and another step, member Part, component, region, layer or part distinguish.Unless clearly indicated by the context, otherwise such as " first " used herein, " Two " and the terms of other numerical terms do not imply that sequence or sequence.Therefore, the introduction for not departing from exemplary embodiment the case where Under, first step, component, assembly unit, region, floor or part discussed below can be referred to as second step, component, assembly unit, area Domain, layer or part.

Space or time relative terms, for example, " before ", " later ", " inside ", " outside ", " following ", " lower section ", " under Herein, for ease of description, these elements can be used to describe an elements or features in portion ", " top ", " top " etc. With the relationship of another elements or features, as shown in the figure.Other than direction shown in figure, space or time relative terms The different directions of equipment or system in being intended to cover using or operating.For example, if the equipment in figure is reversed, by Be described as other elements or feature " lower section " or " below " element will be oriented at other elements or feature " on ".Cause This, exemplary term " lower section " may include above and below direction.Device can otherwise orient (be rotated by 90 ° or In other orientation), and each explain spatial relative descriptor used herein.

It should be appreciated that steps certain for " comprising ", the method for ingredient or feature, composition, device or system is any Narration, in certain substitute variants, can also be susceptible to such method, composition, device.Or system can also " substantially It is made of cited step, ingredient or feature ... ", it is of the invention basic and new therefrom to exclude substantially to change Any other step, ingredient or the feature of clever feature.

In the entire disclosure, numerical value indicates approximate measure or scope limitation, with include with the little deviation of given value and The embodiment of embodiment with described value and the explicit value with described value.In addition to the work provided at the end of detailed description Make except example, all numerical value of the parameter (for example, quantity or condition) in this specification including appended claims should be understood that To be modified in all cases by term " about ", no matter before whether " about " actually appears in numerical value." about " numerical value is indicated Allow some slight inaccurate (to have the accuracy of value some close；Approximately or reasonably close to the value；It is close).If The inexactness provided by " about " is not understood with this ordinary meaning in the art, then " about " used herein indicates extremely Less can by measure and using these parameters commonsense method generate variation.For example, " about " may include less than or equal to 5%, Optionally less than or equal to 4%, it is optionally less than or equal to 3%, 2% is optionally less than or equal to, is optionally less than or equal to Equal to 1%, optionally less than or equal to 0.5%, and in some aspects, optionally less than or equal to 0.1%.

In addition, the disclosure of range includes the disclosure of the range of all values in entire scope and further division, including The endpoint and subrange provided for range.

Exemplary embodiment is described more fully with reference to the drawings.

I. stator module

With reference to Fig. 1 and Fig. 2, the part of exemplary stator 100 (also referred to as stator module 100) is shown.Stator 100 includes Stator body 105, the stator body 105 include multiple laminates 110 (being also referred to as " laminate 110 " herein) and are formed in each Multiple slots 115 (herein also referred to as " slot 115 ") in laminate 110.Multiple slots 115 can be with known in the art any suitable Configuration be formed in each laminate 110.In some embodiments, the laminate 110 and slot 115 of restriction are included therein Stator 100 can be configured for the flowing of magnetic flux radially (referring to Fig. 1 and Fig. 2).In an alternative embodiment, it wraps The stator 100 for including laminate 110 defined therein and slot 115 can be configured for magnetic flux flowing in axial direction. For example, Fig. 3 A depicts the single laminate 110 with multiple slots 115 in a kind of suitable configurations, and Fig. 3 B is shown The component 102 of multiple laminates 110, for the sake of clarity without any other component, plurality of laminate 110 is arranged use It is radially flowed in flux.As shown in Figure 3B, multiple slots 115 limit first end face 112 and second end face 114 jointly.Multiple slots 115 limit tones 107 also between first end face 112 and second end face 114.Laminate 110 may include any suitable Magnetic metal material and its alloy, such as, but not limited to, steel, silicon-containing alloy, iron containing alloy, nickel-containing alloys, cobalt-containing alloy and its Combination.

Referring again to Fig. 1 and 2, stator body 105 may also include winding in slot 115 and lead across multiple conductions of slot 115 Line winding group 120 (for example, copper magnet wiring).Wire winding 120 is referred to as coil windings 120.Wire winding 120 can be put It sets in slot 115, and is longitudinally moved forward and backward between first end face 112 and second end face 114.Although being not shown, at this Text is it is contemplated that wire winding 120 can be placed in slot 115, and between first end face 112 and second end face 114 It moves axially back and forth.Winding end turn can be formed when wire winding 120 leaves the either end of laminate 110.For example, when corresponding Wire winding 120 exited at first end face 112 and be re-directed in subsequent slot 115 and/or be reintroduced When neutralizing to identical slot 115 through identical slot 115, a winding end turn 125 more than first can be formed.A winding terminal more than first Circle 125 can have the first periphery 127.When corresponding wire winding 120 is exited and is reintroduced at second end face 114 It into subsequent slot 115 and/or is re-directed in identical slot 115 and when by identical slot 115, the can be formed A winding end turn 130 more than two.A winding end turn 130 can have the second periphery 132 more than second.In all fields, the first volume around End turn 125 and/or volume Two can be formed as annular ring around first end face 112 and second end face 114 respectively around end turn 130, And adjacent laminate 110.Although understanding in this field figures 1 and 2 show that having the distributed winding of twisted winding Other types of winding construction and winding technique (such as concentratred winding structure and stick are around winding technique) can also with it is considered herein that It and may include in stator body.Multiple laminates 110, a winding end turn 125 and second of wire winding more than 120, first Multiple winding end turns 130 are shown in Fig. 1 and Fig. 2 (and subsequent figure) as solid section.It will be appreciated, however, that multiple Laminate 110 can be multiple individual laminates, and more than 120, first a winding end turn more than 125 and second of wire winding Winding end turn 130 can be multiple individual conductive wires.In addition, as used herein, term " multiple laminates " is covered from one A laminate is to any number of suitable layers casting die as understood in the art (for example, 5 laminates, 10 laminates, 100 A laminate, 1000 laminates etc.).

When motor running, stator generates heat and usually requires cooling, because raised temperature can reduce motor Durability and reduce efficiency.It has been found that include around stator body 105 at least exterior section be arranged polymer it is compound Multiple channels of material housing (as described further below) and the directly or indirectly outside of adjacent stator main body 105 pass through So that heat-transfer fluid was flowed down multiple channels (as described further below) in suitable cooling temperature and can be advantageously carried out Effective cooling to stator body 105.Be contemplated herein flow through multiple channels heat-transfer fluid can also be used for heating stator. Multiple channels can be limited in polymer composite shell, at least part in region between the line in winding end turn In or combinations thereof in.In particular, cooling winding end turn (for example, winding end turn 125, winding end turn 130) may be especially difficult.Example Such as, typical coolant jacket only contact layer casting die, so that the cooling of winding end turn greatly reduces.However, it has been found that by including The polymer composite shell being arranged around the periphery of winding end turn can cool down winding end turn with the efficiency of raising, wherein Multiple channels for receiving heat-transfer fluid can be limited in polymer composite shell.

Therefore, in all fields, as shown in Figures 1 and 2, stator 100 may also include first polymer composite shell Body 135, at least part setting around the first periphery 127 of more than first a winding end turns 125.Stator 100 may also include The second polymer composite material casing that at least part around the second periphery 132 of more than second a winding end turns 130 is arranged 140.Although Fig. 1 and 2 shows first polymer composite material casing 135 and second polymer shell 140, it is susceptible to herein Stator 100 can only include one in first polymer composite material casing 135 and second polymer shell 140.

In addition, stator 100 includes for receiving fluid (such as heating and/or cooling a winding end turn 125 more than first And/or the heat-transfer fluid of a winding end turn 130 more than second) multiple channels 145 (herein also referred to as " channel 145 ").Suitably The example of heat-transfer fluid includes but is not limited to empty gas and water, oil, ethylene glycol, propylene glycol, glycerol, methanol and combinations thereof.Air can be with It supplies from air-conditioning system or is generated by the movement of vehicle.Heat-transfer fluid can supply at a suitable temperature with cooling and/or Stator module 100 is heated, for example, about -40 DEG C to about 120 DEG C, about -40 DEG C to about 20 DEG C, about 10 DEG C to about 120 DEG C, about 20 DEG C To about 100 DEG C or about 20 DEG C to about 90 DEG C.

As shown in Figures 1 and 2, multiple channels 145 can be limited to first polymer composite material casing 135 and second In polymer composite shell 140.Although Fig. 1 and Fig. 2 depict poly- in first polymer composite material casing 135 and second The channel 145 that limits in object shell 140 is closed, but being susceptible to stator 100 herein may include that be limited to first polymer compound Channel 145 in material housing 135 or second polymer shell 140.

In all fields, channel 145 can be oriented with any suitable configuration (for example, circumferential direction, radial direction, branch, intersection, It is close to intersect and combinations thereof) in polymer composite shell (for example, first polymer composite material casing 135, second polymerize Object composite material casing 140) in.For example, as shown in Figure 1, channel 145 can circumferentially prolong around more than first a winding end turns 125 It stretches.In addition, channel 145 can be circumferentially extended around more than second a winding end turns 130.Although Fig. 1 and Fig. 2 are depicted around first The channel 145 that polymer composite shell 135 and second polymer shell 140 circumferentially extend, being susceptible to channel 145 herein can With, such as circumferentially and radially there is in first polymer composite material casing 135 and second polymer shell 140 difference Configuration.As used herein, " circumferentially around " is intended to cover channel 145 along the periphery of winding end turn (for example, the first periphery 127, the second periphery 132) and/or in the interior zone of winding end turn, for example, wherein channel 145 interweaves in winding end turn In conducting wire and around winding end turn (for example, a winding end turn 125 more than first, a winding end turn 132 more than second) circumferentially extending Such configuration.Although being not shown, it is susceptible to polymer composite shell herein (for example, first polymer composite wood Material shell body 135, second polymer composite material casing 140) it can be around the slot (slot 115) of laminate (for example, laminate 110) In the other parts of wire winding (for example, wire winding 120) extend or it be packaged, and channel is (for example, channel 145) it can be limited in this polymer composite shell.

In some embodiments, the channel 145 in first polymer composite material casing 135 can be interconnected amongst one another, including stream Body interconnection and/or physical interconnections.Additionally or alternatively, the channel 145 in second polymer composite material casing 140 can be each other Interconnection, including fluidly connect and/or physical interconnections.As shown in Figure 1, the channel 145 in first polymer composite material casing 135 It can respectively include the first entrance 150 for receiving heat-transfer fluid and the first outlet 155 for removing used heat-transfer fluid. First entrance 150 may include one or more channels 145, and first outlet 155 may include one or more channels 145.Separately Outside or optionally, the channel 145 in second polymer composite material casing 140 can respectively include for receiving heat-transfer fluid Two entrances 160 and second outlet 165 for removing used heat-transfer fluid.Second entrance 160 may include one or more logical Road 145, and second outlet 165 may include one or more channels 145.It is susceptible to first polymer shell 135 and second herein Polymeric shells 140 may include one or more entrances and/or the one or more outlets for entering channel 145.Although being not shown, But the channel 145 in first polymer composite material casing 135 can be in fluid communication, for example, with second polymer composite wood The fluid interconnection of channel 145 and/or physical interconnections in material shell body 140.In such embodiments, channel 145 may include one Or multiple entrance (not shown) and one or more export (not shown).

Additionally or alternatively, polymer composite shell is limited to (for example, first polymer composite wood in channel 145 Material shell body 135, second polymer composite material casing 140) in the case where, channel 145 can be in winding end turn (for example, first A winding end turn 130 of multiple winding end turns more than 125, second) end turn between and wire winding (for example, wire winding 120) Between radially extend.For example, as shown in Figure 4 A, for stator module 400, for the sake of clarity, polymer composite is not shown Material shell body or channel, the concentratred winding end turn that a winding end turn 125a more than first can be used as between end turn with gap 170 are deposited , and wherein gap 170 radially extends between wire winding 120a.145 (not shown) of channel can be in winding end turn It at least part in the gap 170 between 125a and is further radially extended between each wire winding 120a.Fig. 4 B shows The flattening cross-sectional slices for having gone out the stator module 400 on the plane perpendicular to the rotation axis of component are depicted including One polymer composite shell 135, wire winding 120a, laminate 110a and in first polymer composite material casing 135 In be limited to the stator module 400 in channel 145 in gap 170, which radially prolongs between each wire winding 120a It stretches.Although not showing in figure 4b, the channel 145 that limits in first polymer composite material casing 135 can also be It is radially extended in gap 170 between each winding end turn 125a.As shown in Figure 4 B, it is susceptible to first polymer composite wood herein Material shell body 135 (or 140 (not shown) of second polymer composite material casing can reside in the gap between wire winding 120a In 170 at least part.In such embodiments, channel 145 can be with, such as interconnected amongst one another come each other by manifold passage It is in fluid communication.For example, as shown in Figure 4 C, the channel 145 between 175 connecting wire winding 120a of the first manifold passage.Although not It shows, but the second manifold passage can connect the channel 145 in second polymer shell.Additionally or altematively, such as Fig. 4 D Shown, channel 145 between winding 120a can physical interconnections each other.

In an alternative embodiment, channel 145 can be limited between each wire winding of winding end turn (for example, In Between each conducting wire) region at least part in (for example, a winding end turn 125 more than first, a winding end turn more than second 130), for example, wherein winding end turn is bar shaped winding construction.Fig. 5 A shows stator module 500, and for the sake of clarity, this is fixed Polymer composite shell or channel is not shown in sub-component 500, wherein a winding end turn 125b is deposited with item around configuration more than first In.As shown in Figure 5 B, stator module 500 is present in winding end turn 125b along the flattening cross-sectional view of line C-C, region 180 Each wire winding 112 (or conducting wire 112) between.Showing in figure 5 c includes first polymer in stator module 500 Composite material casing 135 and channel 145, which depict first polymer composite material casing 135, winding end turn 125b, laminations Part 110b and the channel 145 limited in region 180 (are not shown, because of each wire winding 112 in winding end turn 125b Between with channel 145 replace).

In an alternative embodiment, wherein the polymer composite shell for defining channel can also be with adjacent stator component In multiple laminates outer surface setting, with further cooling and/or heat stator module.For example, as shown in Figures 6 and 7, it is fixed Sub 600 (also referred to as stator modules 600) may include multiple laminates 110, as described herein multiple windings as described herein Winding, more than as described herein first a winding end turns 125 and more than second a winding end turn 130 as described herein.Stator 600 Further include polymer composite shell 635, can be set around one or more at least part in the following: (i) outer surface 607 of laminate 110；(ii) the first periphery 127 of a winding end turn 125 more than first；(iii) more than second Second periphery 132 of winding end turn 130.In some embodiments, as shown in Figures 6 and 7, polymer composite shell 635 is enclosed Around a winding end turn 130 in the first periphery more than 127 and second of a winding end turn 125 in the outer surface of laminate 110 more than 607, first The second periphery 132 setting.

Multiple channels 145 as described herein are limited in polymer composite shell 635.It channel 145 can be poly- In compound composite material shell 635 with any suitable configuration orientation, for example, circumferential direction, radial direction, branch, intersection, it is crossed longitudinally and A combination thereof.In some embodiments, channel 145 can surround one of the following or multiple circumferentially extendings: (i) laminate 110 Outer surface 607；(ii) a winding end turn 125 more than first；(iii) second group of multiple winding end turn 130.Such as the institute of Fig. 6 and 7 Show, channel 145 can be circumferentially extended around following direction: the outer surface 607 of (i) laminate 110；(ii) a winding terminal more than first Circle 125；(iii) more than second a winding end turn 130.Although being not shown, herein it is contemplated that channel 145 can be only around The outer surface 607 of laminate 110 circumferentially extends, rather than circumferentially extends around more than first a winding end turns 125；(iii) A winding end turn 130 more than two.

In some embodiments, at least part in the channel 145 in polymer composite shell 635 can be mutually Connect, including fluid interconnection and/or physical interconnections.As shown in Figures 6 and 7, the channel 145 in polymer composite shell 635 can Third outlet 655 including the third entrance 650 for receiving heat-transfer fluid and for removing used heat-transfer fluid.Third enters Mouth 650 may include one or more channels 145, and third outlet 655 may include one or more channels 145.And Fig. 6 and Fig. 7 In show two third entrances 650 and third outlet 655, being susceptible to stator 600 herein can only include that a third enter Mouth 650 or more than two third entrance 650 and/or more than one third outlet 655.650 He of third entrance is contemplated herein Third outlet 655 can reside at each position in polymer composite shell 635, for example, third entrance 650 and the Three outlets 655 can reside in the polymer composite shell 635 near laminate 110, for only cooling and/or heating Laminate 110.

In all fields, heat-transfer fluid can supply reservoir or supply from least one by least one pump (not shown) Channel (not shown) is supplied at least one entrance (for example, first entrance 150, second entrance 160, third entrance 650) and is located at Polymer in stator module (for example, stator module 100, stator module 400, stator module 500, stator module 600) is compound Material housing is (for example, first polymer composite material casing 135, second polymer shell 140, polymer composite shell 635) in.Pump and supply container can reside near stator module.Optionally, heat-transfer fluid can flow through cooler and (not show Heater (not shown) can be flowed through to increase heat transfer stream with the temperature or heat-transfer fluid that further decrease heat-transfer fluid out) The temperature of body.

In any embodiment, each channel 145 can have any suitable cross section, for example, substantially circular cross Section, the cross section of substantial rectangular or combinations thereof.As understood herein, " substantially circular " may include round and ellipse Cross section, and the size of cross section can deviate in some respects.As understood herein, " substantial rectangular " may include just Square cross section, and the size of cross section can deviate in some respects.Each channel 145 can have about 10 μm to about 25mm, about 50 μm to about 15mm, about 100 μm to about 10mm, about 500 μm to about 10mm, about 1mm to about 10mm, or about 1mm is to about The diameter of 5mm.

In some embodiments, as shown in figure 8, it illustrates the cross section in single channel 145, which may include Shell 147 with wall thickness 149.Wall thickness 149 can in about 1 μm to about 5mm, about 50 μm to about 2.5mm, about 100 μm to about 1mm, Or in the range of about 200 μm to about 800 μm.In all fields, shell 147 may include metal (for example, stainless steel, copper, aluminium), gather Close object (epoxy resin, nylon, polyphthalamide (PPA), polyphenylene sulfide (PPS), nylon, polypropylene (PP), polyethylene (PE)), polymer composites, ceramics or combinations thereof.

It as described further below, can be by will include that the channel precursor material of expendable material is applied to stator with shape At intermediate stator component, the placement of intermediate stator component is introduced into mold, before curable polymer in a mold, by polymer precursor Body with formed polymer composite shell (for example, first polymer composite material casing 135, second polymer shell 140, Polymer composite shell 635), and expendable material is removed to form multiple channels 145.

In any embodiment, polymer composite shell is (for example, first polymer composite material casing 135, second Polymeric shells 140, polymer composite shell 635) it may include that any suitable polymer and optionally a variety of are suitable Reinforcing fiber and/or band.The example of suitable polymer includes but is not limited to thermosetting polymer (for example, thermosetting property tree Rouge), thermoplastic polymer (for example, thermoplastic resin), elastomer and combinations thereof.Preferred polymer includes but is not limited to epoxy Resin, phenolic resin, vinyl esters, bismaleimide, polyether-ether-ketone (PEEK), polyamide, polyimides and polyamide acyl Imines.Suitable reinforcing fiber and/or the example of band include but is not limited to carbon fiber, carbon fiber strips, glass fibre, aromatics Fypro, polyethylene fibre, organic fiber, metallic fiber, ceramic fibre, basalt fibre, quartz fibre, graphite are fine Dimension, nanofiber, boron fibre and combinations thereof.Particularly, reinforcing fiber and/or band are glass fibre, carbon fiber and/or carbon fiber Tie up band.Reinforcing fiber can be continuous fiber or discontinuous fibre.Particularly, reinforcing fiber is continuous fiber.Advantageously, it wraps Polymer composite shell containing polymer composites as described herein is (for example, first polymer composite material casing 135, second polymer shell 140, polymer composite shell 635) there can be about 100MPa to about 2000MPa, about The compressive strength of 500MPa to about 1000MPa or about 1000MPa to about 1500MPa.

II. the method for stator module is made

Additionally provide the method for manufacturing stator module described herein.This method may include applying step, the step packet It includes and the channel precursor material including expendable material is applied to stator to form intermediate stator component.Stator may include such as this paper institute The multiple laminates (for example, laminate 110) stated, each laminate include multiple slots (for example, slot 115) as described herein. Stator further include the multiple wire windings (for example, wire winding 120) as described herein being arranged in slot, as described herein A winding end turn (for example, winding end turn 125) more than first and more than second a winding end turn as described herein are (for example, winding End turn 130).The exemplary description for applying step is shown in figures 9 a and 9b.Fig. 9 A shows the flattening top view of stator body, The stator body includes more than the first a conducting wires adjacent with the first end face 112 of multiple slot (not shown) of multiple laminates 110 Winding 125.In figure 9 a, applying step includes circumferentially applying channel precursor material 908 around more than first a winding end turns 125 To form intermediate stator component 909.Additionally or alternatively, applying step includes surrounding more than second a winding end turns 130 circumferentially Apply channel precursor material 908, as shown in fig. 9b, it illustrates the flattening cross sections of intermediate stator component 909.In any reality It applies in example, it can be at the position adjacent with more than first a winding end turns 130 of a winding end turn more than 125 and/or second with any Suitable adhesive or frenulum keep channel precursor material 908.Although being not shown, it is susceptible to channel precursor material herein 908 can be applied to it is at least part of wire winding 120 or interior.

In an alternative embodiment, applying step may include in winding end turn 125a a more than wire winding 120a and first Winding end turn between radially apply channel precursor material 908 to form intermediate stator component 1009, as shown in Figure 10 A.Figure 10A shows the flattening cross-sectional slices of the stator module 400 in the plane of the rotation axis perpendicular to the component in Fig. 4 A, At least including wire winding 120a, laminate 110a and the radial gap 170 being present between each wire winding 120a Channel precursor material 908 in a part.Although being not shown, applies step and be included between winding end turn 125a radially Apply channel precursor material 908.Although being not shown, additionally or alternatively, which be may further include Radially apply channel precursor material 908 between each wire winding and each winding end turn in a winding end turn more than two.

In another alternate embodiment, apply step may include channel precursor material 908 is applied to more than first around At least part in the region between each wire winding 112 (or conducting wire 112) of group end turn 125b is to form middle layer stator Component 1109, as shown in Figure 11 A.Figure 11 A depicts the cross-sectional slices of the stator module 500 of the line C-C along Fig. 5 A, including Winding end turn 125b, laminate 110b and it is present in the region 180 more than first between the wire winding 112 of a winding end turn 125b In channel precursor material 908 (being not shown, because there are channel precursor materials 908).Although being not shown, alternatively or additionally Ground, applying step can also include being applied to channel precursor material more than second between each wire winding of a winding end turn At least part region in region.

In another alternate embodiment, applying step may include leading to around one of the following or multiple circumferentially apply Road precursor material 908:(i) multiple laminates 110 outer surface 607, (ii) more than first a winding end turn 125, and (iii) second Multiple winding end turns 130, to form intermediate stator component 1209, as illustrated in fig. 12.Optionally, it as shown in Figure 12 B and 12C, inserts Intermediate stator component 1209 can be applied to by entering part 123, to obtain the additional rigidity of structure, to form intermediate stator component 1209a.Insertion piece 123 may include metal or continuous fiber.Optionally, as indicated in fig. 12 c, insertion piece 123 can be attached to carbon Fibrous ribbon 133 is to form intermediate stator component 1209b.For clarity, in Figure 12 B and Figure 12, channel precursor is not shown Material 908.Alternatively, the insertion piece 123 for being optionally attached to carbon fiber strips 133 can be before applying channel precursor material 908 Apply laminate 110.

In any embodiment, this method further includes encapsulating step, including by intermediate stator component (for example, intermediate stator Component 909, intermediate stator component 1009, intermediate stator component 1109, intermediate stator component 1209) it is placed on mold (not shown) In, polymer precursor is introduced into mold, and under suitable conditions before solidification (for example, cooling, reaction, crosslinking) polymer Body, to form the solid polymer stator module for including polymer.Polymer precursor may include be used to form polymer any Suitable polymer precursor or polymer, for example, being used to form thermosetting polymer (for example, thermosetting resin), thermoplastic poly Close object (for example, thermoplastic resin), elastomer and combinations thereof.Preferred polymer includes but is not limited to epoxy resin, phenolic aldehyde tree Rouge, vinyl esters, bismaleimide, polyether-ether-ketone (PEEK), polyamide, polyimides and polyamidoimide.Some In embodiment, polymer composite shell is (for example, first polymer composite material casing 135, second polymer composite material Shell 140, polymer composite shell 635) it can be formed by injection moulding.For example, mold may include for receiving polymerization The void space that the shell of object precursor limits.The void space that the shell limits can be by the metal being present in mold or polymerization Object borders, which depict the shapes of polymer composite shell.Polymer precursor can be introduced into mold, then be solidified (for example, cooling, reaction, crosslinking) is to form comprising polymer composite shell (for example, first polymer composite material casing 135, second polymer composite material casing 140, polymer composite shell 635) solid polymer stator module.Or Person, polymer composite shell is (for example, first polymer composite material casing 135, second polymer composite material casing 140, polymer composite shell 635) it can be formed by other suitable technologies, such as, but not limited to, pultrusion, reaction Injection moulding, compression forming, prepreg molding (in autoclave or as compression forming), resin transfer moulding and vacuum aided Resin transfer moulding.

For example, as shown in Figure 9 C, by the way that intermediate stator component 909 is placed in mold (not shown), will be before polymer Body (not shown) is introduced into mold and curable polymer precursor is come with forming solid polymer stator module 912 in the encapsulating step phase Between formed solid polymer stator module 912.The polymer stator module 912 may include around more than first a winding end turns 125 The first periphery 127 at least part setting first polymer composite material casing 135 and surround more than second a winding terminals The second polymer composite material casing 140 of at least part setting of second periphery 132 of circle 130.Channel precursor material 908 It is arranged in first polymer composite material casing 135 and second polymer composite material casing 140.First polymer composite wood Material shell body 135 and second polymer composite material casing 140 include polymer as described herein.Although being not shown, It is susceptible to the other parts that polymer precursor can be introduced into stator module herein, for example, polymer precursor can be with contact wire At least part of winding 120, for example, being applied to wherein or the part of internal wire winding 120 with channel precursor material.

In an alternative embodiment, as shown in Figure 10 B, by the way that intermediate stator component 1009 is placed on mold (not shown) In, polymer precursor (not shown) is introduced into mold, and curable polymer precursor is to form solid polymer stator module 1012 to be formed solidification stator module 1012 during encapsulating step.Solid polymer stator module 1012 may include laminate 110a, more than first a winding end turn 125a, the first polymer composite material casing 135 including polymer as described herein, And the channel precursor material 908 in first polymer composite material casing 135 is set.Although being not shown, solid is poly- Closing object stator module 1012 may further include a winding end turn more than second, and second including polymer as described herein is poly- Compound composite material shell, and the channel precursor material being arranged in second polymer composite shell body.

In another alternate embodiment, as shown in Figure 11 B, by the way that intermediate stator component 1109 is placed on mold (not Show) in, polymer precursor (not shown) is introduced into mold, curable polymer precursor is to form solid polymer stator pack Part 1112 to form solid polymer stator module 1112 during encapsulating step.Solid polymer stator module 1112 may include Laminate 110b, the first polymer composite material casing 135 comprising polymer as described herein, and be arranged more than first The channel precursor material 908 in region between the conducting wire 112 of a winding end turn 125b.Although being not shown, solid polymerization Object stator module 1112 may further include second polymer composite material casing comprising polymer as described herein, And the channel precursor material in the region more than second between the conducting wire of a winding end turn is set.

In another alternate embodiment, as indicated in fig. 12d, by the way that intermediate stator component 1209 is placed on mold (not Show) in, polymer precursor (not shown) is introduced into mold and curable polymer precursor is to form solid polymer stator pack Part 1212 to form solid polymer stator module 1212 during encapsulating step.Solid polymer stator module 1212 may include Laminate 110, the polymer composite shell 635 comprising polymer as described herein, and setting are compound in polymer Channel precursor material 908 in material housing 635.Polymer composite shell 635 can surround arranged below: (i) lamination At least part of the outer surface 607 of part 110；(ii) at least part of the periphery 127 of a winding end turn 125 more than first；With (iii) at least part of the periphery 132 of a winding end turn 130 more than second.Optionally, as shown in figure 12e, it optionally connects Insertion piece 123 to carbon fiber strips 133 can be applied to intermediate stator component 1209 for increasing the rigidity of structure to form solid Polymer stator module 1212a.

In some embodiments, this method may further include, such as in the application step or the encapsulating step process In, optionally adjacent to the intermediate stator component (for example, intermediate stator component 909, intermediate stator component 1009, intermediate stator group Part 1109, intermediate stator component 1209) arrange multiple reinforcing fibers and/or band.The example packet of the reinforcing fiber and/or band Include but be not limited to carbon fiber strips and selected from carbon fiber, glass fibre, aramid fibre, polyethylene fibre, organic fiber, Metallic fiber, ceramic fibre, basalt fibre, quartz fibre, graphite fibre, nanofiber, boron fibre and combinations thereof it is continuous Fiber.Reinforcing fiber can be prepared by any other suitable method known in the art, such as braiding, weaving, suture, needle It knits, pre-preg, manually lay and robot or manual placement tow.

In some embodiments, polymer composites can be formed by using the band of composite precursor materials, such as be increased Strong fiber.Composite material could be formed with one or more layers, wherein every layer can contact and/or be overlapped the material based on fiber come Form band.Reinforcing fiber also may include polymer precursor (for example, polymer).Polymer precursor can be cured (for example, cold But, react, be crosslinked), therefore can be used for that single-layer or multi-layer being bonded together in polymer composites.Usually it can be used Various methods introduce polymer precursor to impregnate matrix composite material (for example, reinforcing fiber) system based on fiber: wet-wound group (or laying), pre-preg (referred to as " presoaking ") and resin transfer formation.For wet-wound group, dry fibers reinforcing material is (for example, enhancing Fiber) polymer precursor (for example, resin) can be used when in use, usually soaked by submergence bath.It is (pre- for pre-preg Leaching), polymer precursor is soaked into the material based on fiber in advance, and generally include partially cured polymer precursor to have It the step of viscosity or sticky consistency (also referred to as B-stage is partially cured), then rolls and presoaks the material based on fiber for making later With.Prepreg composite system is tended to using aathermoset resin system, can be by raised temperature-curable, when solidification Between be about 1 minute to about 2 hours (depending on solidification temperature).However, some preimpregnation materials can be used with actinic radiation (example Such as, ultraviolet radioactive (UV)) cured resin.For resin transfer moulding, dry fibre reinforced materials can be put into mold In, and can be under stress (for example, about 10psi to about 2000psi) enters resin infusion in mold.Note known in the art Penetrating forming technique can also be used for for polymer precursor (for example, resin) being introduced into reinforcing material, especially include in reinforcing material In the case where discontinuous fibre.For example, can will be injected comprising the precursor of polymer precursor (for example, resin) and reinforcing material or It inculcates in the space or mold of restriction, makes precursor cures then to form polymer composites.Term " injection molding " further includes Use the reaction injection molding(RIM) of thermosetting polymer.

Certain in terms of other, this introduction also contemplates attachment step, the step for example, by working surface (for example, Intermediate stator component 909, intermediate stator component 1009, intermediate stator component 1109, intermediate stator component 1209) nearby, it is internal And/or filament wound, braiding or the weaving of top are to apply the reinforcing material (for example, reinforcing fiber) based on fiber.This method It optionally include that polymer precursor (for example, unreacted resin) composition is applied or be introduced into the strengthening material based on fiber In material or on.When application, it is intended that unreacted polymer precursor compound is wetted on the reinforcing material based on fiber, because This can be coated on the surface of the reinforcing material based on fiber or absorb/be impregnated into and (be used in the reinforcing material based on fiber For example, in reinforcing fiber hole or opening in).After polymer precursor is introduced the region with reinforcing material, so Solidification (for example, solidification or reaction) is afterwards to form polymer composites.It can also be applied by filament wound, braiding or weaving Add material of the pre-preg based on fiber.

After encapsulating step, (for example, heating) solid polymer stator pack can be further processed in removal step Part (for example, solid polymer stator module 912, solid polymer stator module 1012, solid polymer stator module 1112, Solid polymer stator module 1212) to remove the expendable material of channel precursor material 908, to be formed in following one or more Multiple channel 145:(i of middle restriction) first polymer composite material casing 135；(ii) second polymer composite material casing 145；(iii) polymer composite shell 635；(iv) region more than first between the conducting wire of a winding end turn；(v) second Region between the conducting wire of multiple winding end turns.For example, Fig. 9 D, 10C, 11C, 12F show and are formed after the removal step Channel 145.

As shown in FIG. 13A, channel precursor material 908 (for example, optical fiber) includes expendable material 920.In some embodiments, As shown in Figure 13 B, precursor 908a in channel may also include the 147 (example of shell for including as described herein or encapsulating expendable material 920 Such as, metal, polymer, polymer complex, ceramics or combinations thereof).In any embodiment, expendable material 920 may include It is able to carry out one of following or a variety of material: fusing, evaporation, detonation and dissolution.The example of suitable expendable material 920 Including but not limited to metal, polymer, scattering material and combinations thereof.Non-limiting metal may include solder comprising lead, tin, Zinc, aluminium, suitable alloy etc..Non-limiting polymer may include polyvinyl acetate, polylactic acid, polyethylene, polystyrene.It is non- Restricted detonation material may include ceramics, salt (for example, potassium nitrate), black powder, charcoal, pentaerythritol tetranitrate, flammable Metal, flammable oxide, thermit, nitrocellulose, thermal fiber element, flashlight powder, smokeless powder and combinations thereof.Alternatively or additionally Ground, expendable material 920 can further change fusing or degradation behavior with catalyst treatment or chemical modification.In some implementations In example, in the case that in channel, precursor 908a includes shell 147, expendable material 920 is also possible to gas, such as air.

Therefore, removal step may include making the volatilization of expendable material 920, fusing, detonation or degradation, or can dissolve sacrificial Domestic animal material 920 is to generate degradation product.For example, expendable material 920 can be heated to certain temperature (for example, about 150 DEG C to about 200 DEG C) or be subjected to substantially evaporating, melt or detonation expendable material 920 but substantially non-degradable polymer composite shell With the reaction of optional reinforcing fiber.Optionally any suitable solvent (such as, but not limited to, acetone) is applied under stiring It is added to dissolve them on material, as long as solvent is substantially non-degradable or dissolves polymer composite shell and optional enhancing Fiber.Alternatively, suitable sour (for example, hydrochloric acid, sulfuric acid, nitric acid etc.) can be used to etch expendable material.Although not showing Out, but herein it is envisaged that method described herein further includes providing close to channel precursor material 908, for example, passing through brill Enter polymer composite shell 8, so as to execute removal step on expendable material.It can be for example, by polymer Composite material casing, which applies vacuum or introduces gas, enters polymer composite shell, and catabolite discharge polymer is answered Condensation material shell come remove degradation product with polymer composite shell (for example, first polymer composite material casing 135, Second polymer composite material casing 140, polymer composite shell 635) in formed channel 145.In some embodiments, In the case that precursor material 908 includes shell 147 in channel, shell 147 is retained after removing degradation product.

In some optional embodiments, intermediate stator component 909 can be placed in stator case 950, as shown in figure 14, Then intermediate stator component 909 is placed in 950 (not shown) of stator case in a mold to execute encapsulating step.In addition or Optionally, solid polymer stator module 912 can be optionally placed in stator case 950 before removing expendable material 920, As shown in Figure 15.

Additionally or alternatively, this method may include for other motorized steps of group.For example, sacrificing material removing It, can be by providing and assembling axis 500, bearing 505, case cover 510 and for close to third entrance 650 and the after material 920 Three export 655 pipe fitting 515 to assemble motor 300, as shown in figure 16.

The foregoing description of embodiment is provided for the purpose of illustration and description.It is not intended to exhaustion or limitation originally It is open.The each element or feature of specific embodiment is generally not limited to this particular embodiment, but being under applicable circumstances can Exchange and can be used in selected embodiment, even if being not shown or described in detail.It equally can also be in many ways Change.These changes should not be considered as the disengaging disclosure, and all such modifications are intended to include within the scope of this disclosure.