Patent ID: 7077990
Filing Date: 2006-07-18
Classification: H02K,Y10T

Abstract:
1. A method for making a balanced stator assembly having a high density thermally-conductive housing, comprising the steps of: providing a weight balanced molten polymer composition of about 20% to about 80% by weight of a base polymer matrix and about 30% to about 80% by weight of a thermally-conductive, electrically-insulating material and a total polymer composition density of greater than 2.5 g/cc and a total electrical resistivity kept at 1×10 providing a motor stator comprising a magnetically-inducible non-uniform core with poles extending therefrom, wherein the poles have wire windings for conducting electrical current said wire winding having a wire density; and injecting the molten polymer composition into a mold containing the stator and maintaining the composition under high pressure until it cools to form a stator assembly having a thermally-conductive housing, wherein said housing overcomes imbalances in said stator created by the non-uniformity of said core wherein a density differential between said polymer composition and said wire density is less than 6.4 g/cc, and wherein the composition has a thermal conductivity of at least about 0.6 W/m° K.