Stators having female connectors and methods for forming female connectors integral with the stator winding conductors

Abstract

Stators having female connectors and methods for forming female connectors integral with the stator winding conductors, thereby avoiding the necessity of use of a separate female connector. A typical connector in accordance with the present invention has a first length of the wire adjacent an end of the wire striped of insulation, and a second length of the wire adjacent the end not greater than the first length of wire being bent in a substantially closed loop, the loop preferably being pressed flat so as to have a thickness less than the wire. Also preferably the wire bends in a first direction and then bends in a circular arc to form the loop, the center of the loop being substantially aligned with a center of the wire. Various embodiments are disclosed as are exemplary simple methods for forming the female connector.

1 . A motor stator comprising:
 a stator core having windings formed of rectangular insulated wire;   at least one of the rectangular insulated wires having one end that is longer than other rectangular insulated wires to extend a first length beyond stator core winding end turns;   a second length of the extended wire adjacent the end of the extended wire being striped of insulation, the second length being less than the first length;   a third length of the extended wire adjacent the end not greater than the second length of wire being bent in a substantially closed loop about an axis perpendicular to two opposite sides of the extended wire.   
     
     
         2 . The motor stator of  claim 1  wherein the loop is pressed flat so as to have a thickness less than the thickness of the wire. 
     
     
         3 . The motor stator of  claim 2  wherein after pressing, an opening through a center of the loop is further opened to a predetermined diameter. 
     
     
         4 . The motor stator of  claim 2  wherein the second length is greater than the third length, and wherein the loop is pressed flat over a length between the second length and the third length. 
     
     
         5 . The motor stator of  claim 1  wherein the third length of wire bends in a first direction and then bends in a circular arc to form the loop, a center of the loop being substantially aligned with a center of the wire. 
     
     
         6 . A motor stator comprising:
 a stator core having windings formed of flat insulated solid copper wire;   at least one of the flat insulated solid copper wires having one end that is longer than other flat insulated solid copper wires to extend a first length beyond stator core winding end turns;   a second length of the extended wire adjacent the end of the wire being striped of insulation, the second length being less than the first length;   a third length of the extended wire adjacent the end not greater than the second length of the extended wire being bent in the plane of the width of the extended wire in a first direction and then in a circular arc in a second direction opposite the first direction to form a substantially closed loop, a center of the loop being substantially aligned with a center of the extended wire.   
     
     
         7 . The motor stator of  claim 6  wherein the loop is pressed flat so as to have a thickness less than the thickness of the wire. 
     
     
         8 . The motor stator of  claim 7  wherein after pressing, an opening through a center of the loop is further opened to a predetermined diameter. 
     
     
         9 . The motor stator of  claim 7  wherein the second length is greater than the third length, and wherein the loop is pressed flat over a length between the second length and the third length. 
     
     
         10 . A method of fabricating a motor stator comprising:
 winding a motor stator core with an insulated rectangular wire, leaving one end of at least one insulated rectangular wire extending a first length beyond winding end turns;   stripping the insulation from a second length of the extended wire adjacent the end thereof, the second length being less than the first length; and,   bending the end of the extended wire in a circular arc in a plane parallel to opposite sides of the wire to form a substantially closed loop.   
     
     
         11 . The method of  claim 10  further comprised of pressing the loop to flatten the wire. 
     
     
         12 . The method of  claim 11  further comprised of punching out the wire at the center of the loop to provide a predetermined diameter opening through the loop. 
     
     
         13 . The method of  claim 11  wherein pressing the loop also comprises pressing a length of wire between the second and the third length. 
     
     
         14 . The method of  claim 10  wherein bending the end of the extended wire comprises bending the end of the extended wire in a first direction in the plane and bending the extended wire in a second direction opposite the first direction in a circular arc in the plane to form a substantially closed loop having its center substantially aligned with the center of the width of the extended wire. 
     
     
         15 . A method of fabricating a motor stator comprising:
 winding a motor stator core with insulated flat wire having a width greater than its thickness, leaving one end of the insulated flat wire extending a first length beyond winding end turns;   the stripping the insulation from a second length of wire adjacent the end thereof, the second length being less than the first length; and,   bending the end of the extended wire, along a third length less than the second length, in a first direction in the plane of the width of the wire and bending the wire in a second direction opposite the first direction in a circular arc in the plane of the width of the wire to form a substantially closed loop having its center substantially aligned with the center of the width of the wire; and,   pressing the loop to flatten the wire.   
     
     
         16 . The method of  claim 15  further comprised of punching out the wire at the center of the loop to provide a predetermined diameter opening through the loop. 
     
     
         17 . The method of  claim 15  wherein the second length of wire is greater than the length of wire required to form the loop, and wherein the pressing of the loop also comprises pressing a length of wire between the second length and the third length. 
     
     
         18 . A motor stator comprising:
 a stator core having windings formed of insulated wire;   at least one of the rectangular insulated wires having one end that is longer than other rectangular insulated wires to extend a first length beyond stator core winding end turns;   the insulation being stripped off the end of the extended wire over a second length;   a third length of the extended wire adjacent the end and not greater than the second length of wire being bent in a substantially closed loop, the loop being pressed flat so as to have a thickness less than the wire.   
     
     
         19 . The motor stator of  claim 18  wherein the second length is greater than the second third, and wherein the loop is pressed flat over a length between the second length and the third length. 
     
     
         20 . The motor stator of  claim 18  wherein the third length of wire bends in a first direction and then bends in a circular arc to form the loop, a center of the loop being substantially aligned with a center of the wire. 
     
     
         21 . A method of fabricating a motor stator on an insulated wire comprising:
 winding a motor stator core with insulated wire having a, leaving one end of the insulated wire extending a first length beyond winding end turns;   stripping the insulation from the end of the extended wire a second length of wire adjacent the end thereof;   bending the end of the wire in a circular arc to form a substantially closed loop; and, pressing the loop to flatten the wire.   
     
     
         22 . The method of  claim 21  wherein the pressing of the loop also comprises pressing a length of wire adjacent the loop. 
     
     
         23 . The method of  claim 21  wherein bending the end of the extended wire comprises bending the end of the extended wire in a first direction before bending the extended wire in a second direction opposite the first direction in a circular arc to form a substantially closed loop having its center substantially aligned with center of the wire.