Motor

Abstract

A motor has a stator substantially encapsulated within a body of thermoplastic material. A plurality of different motors are made by encapsulating different stators using the same mold tool. The stators may differ with respect to one or more of the following: i) the number of turns of wire per winding, ii) the number of poles, iii) the diameter of the stator, and iv) the thickness of the stator The stators are then used to build motors with different characteristics. The process produces benefits associated with development time and cost for new motor configurations.

1 . A method of manufacturing a variety of motors comprising: 
 a) providing a plurality of stators having poles with windings thereon, the stators differing from one another in one or more of the properties of: 
 i) the number of turns of wire per winding;  
 ii) the number of poles;  
 iii) the diameter of the stator; and  
 iv) the thickness of the stator;  
   b) providing a common mold tool;    c) holding a first stator in the mold tool and adding a phase change material to substantially encapsulate the first stator;    d) using the encapsulated stator, a bearing and a shaft to build a first variety of motor;    e) holding a second stator having properties different than the first stator in said mold and adding a phase change material to substantially encapsulate the second stator; and    f) using the encapsulated second stator, a bearing and a shaft to build a second variety of motor.    
   
   
       2 . The method of  claim 1  wherein the phase change material is different for the first and second stators.  
   
   
       3 . The method of  claim 1  wherein the phase change material completely encases the stator so that no external surfaces are exposed.  
   
   
       4 . The method of  claim 1  wherein the stator is constructed into a fluid pump.  
   
   
       5 . The method of  claim 1  wherein the stator is constructed into a generator.  
   
   
       6 . A method of manufacturing a variety of motors comprising: 
 a) providing a plurality of rotors having poles with windings thereon, the rotors differing from one another in one or more of the properties of: 
 i) the number of turns of wire per winding;  
 ii) the number of poles;  
 iii) the diameter of the rotor; and  
 iv) the thickness of the rotor;  
   b) providing a common mold tool;    c) holding a first rotor in the mold tool and adding a phase change material to substantially encapsulate the first rotor;    d) using the encapsulated rotor, a bearing and a shaft to build a first variety of motor;    e) holding a second rotor having properties different than the first stator in said mold and adding a phase change material to substantially encapsulate the second rotor; and    f) using the encapsulated second rotor, a bearing and a shaft to build a second variety of motor.    
   
   
       7 . The method of  claim 6  where the phase change material is different for the first and second rotors.  
   
   
       8 . The method of  claim 6  wherein the phase change material completely encases the rotor so that no external surfaces are exposed.  
   
   
       9 . The method of  claim 6  wherein the stator is constructed into a fluid pump.  
   
   
       10 . The method of  claim 6  wherein the stator is constructed into a generator.  
   
   
       11 . A plurality of motors comprising first and second motors, each motor comprising a stator having poles with windings thereon and a phase change material substantially encapsulating the stator, the phase change material having been molded in a common mold tool for all motors in the plurality of motors, the motors also each comprising at least one bearing and a shaft, the stators in the first and second motors differing from one another in one or more of the properties of: 
 i) the number of turns of wire per winding;    ii) the number of poles;    iii) the diameter of the stator; and    iv) the thickness of the stator.    
   
   
       12 . The plurality of motors of  claim 11  wherein the phase change material is different for the stators in the first motors compared to the stators in the second motors.  
   
   
       13 . The plurality of motors of  claim 11  wherein the phase change material completely encases the stator so that no external surfaces are exposed.