Abstract:
A stator deflector assembly for an electric motor includes a plastic deflector formed to conform to a shape of the stator, an absorbent media envelope supported by the deflector, and a holding mechanism for holding the absorbent media envelope at least partially against the deflector. The absorbent media envelope is wrapped over the deflector, and the holding mechanism includes cotter pins inserted into protrusions having recesses which are formed on the deflector, and heat-staked pins which are melted against the absorbent media envelope. A wire is looped through the heads of the cotter pins to remove them after the stator deflector assembly is inserted into the motor housing. In another embodiment, the holding mechanism is an adhesive. Coolant is injected from the motor over and deflected over and absorbed by the absorbent media envelope, and passed through holes in the absorbent media envelope and deflector, to cool the stator windings.

Description:
FIELD OF THE INVENTION 
     The present invention relates to a stator deflector apparatus for deflecting coolant liquid injected from an electric motor over the windings of a stator of the electric motor, and to a method of assembling the stator deflector apparatus. 
     BACKGROUND OF THE INVENTION 
     In general, prior art electric motors include a rotatable rotor and a fixed stator. Stators are normally formed of a series of thin, flat plates stacked to form a solid body. Coils or windings are positioned in pre-formed slots in the plates, extending through the stack, with ends of the coils looping at each end of the stack to form end turns. The stator is normally cooled by air blowing through passages in the stator. Coolant in the form of oil injected from the motor, has also been used to cool the stator windings. However, the oil has often been misdirected and the stator windings have not been sufficiently cooled by this method. 
     Further, recent technological advances in electric hybrid motors, primarily for use in automobile manufacturing, have highlighted the problem where the stator windings of the electric hybrid motors have become very hot, and conventional cooling methods have been insufficient to cool down the motors. In particular, as stated above, the oil injected from the electric hybrid motor and used to cool the stator windings has not been directed appropriately to the stator windings, and have proven insufficient in cooling the stator windings. 
     SUMMARY OF THE INVENTION 
     Accordingly, an object of the present invention is to provide a stator deflector assembly which can cool the windings of a stator of an electric motor, in particular an electric hybrid motor, without a marked increase in complexity and in cost. 
     To this end, the present invention includes a stator deflector assembly having a deflector formed to conform to a shape of the stator; a fluid retaining and deflecting mechanism supported by the deflector; and a holding mechanism which holds the fluid retaining and deflecting mechanism at least partially against the deflector. 
     The fluid retaining and deflecting mechanism is an absorbent media envelope, which is a layered rolled felt in a preferred embodiment, and the felt is wrapped over the deflector. 
     The holding mechanism includes cotter pins which secure the felt to the deflector by inserting the cotter pins into protrusions having recesses therein, which are molded with the deflector. Also, the holding mechanism includes heat-staked pins which are also molded with the deflector, and which protrude through the wrapped felt and are melted against the felt to secure the felt to the deflector. 
     In a second embodiment of the present invention, the heat-staked pins and cotter pins are replaced by an adhesive, which at least partially adheres the felt to the deflector. 
     In a method of assembling the apparatus for cooling the windings of a stator, the steps include molding the deflector into a shape which corresponds to a shape of the stator; folding a fluid retaining and deflecting mechanism over the deflector; adhering the fluid retaining and deflecting mechanism at least partially to the deflector; and positioning the stator deflector assembly onto the stator in the electric motor. 
     As stated above, the fluid retaining and deflecting mechanism is an absorbent media envelope, which is a layered rolled felt in a preferred embodiment, and the holding mechanism includes cotter pins which secure the felt to the deflector, and heat-staked pins which are also molded with the deflector. 
     The adhering step includes heat-staking pins disposed on the deflector against the fluid retaining and deflecting mechanism; and inserting pins through recesses within protrusions protruding from the deflector, to hold the fluid retaining and deflecting mechanism against the deflector. The adhering step also includes using an adhesive, to adhere the fluid retaining and deflecting mechanism at least partially against the deflector. 
     Once the assembled stator deflector apparatus is placed in the motor housing, a wire which is disposed through the heads of the cotter pins, is pulled, such that all the cotter pins are removed and the felt is released from the surface of the deflector. Thus, the stator deflector assembly is able to catch the coolant using the felt, as the coolant is injected from the motor over the stator windings. The coolant is soaked into the felt and seeps through holes in the felt to the deflector, successfully soaking the stator windings of the motor. Thus, the task of cooling the stator windings, which ensures that the electric motor operates within a safe temperature range, is achieved. 
     There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described below and which will form the subject matter of the claims appended hereto. 
     In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract included below, are for the purpose of description and should not be regarded as limiting. 
     As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Additional features, details, and advantages of the invention, will become evident from the following description and the drawing, wherein: 
     FIG. 1 is a perspective drawing of the inner side of the completed stator deflector assembly according to a first embodiment of the present invention. 
     FIG. 2 is a perspective drawing of the outer side of the completed stator deflector assembly according to a first embodiment of the present invention. 
     FIG. 3 is a plan view of one embodiment of the absorbent media envelope. 
     FIG. 4 is a perspective drawing of the outer side of the deflector according to a first embodiment of the present invention. 
     FIG. 5 is a perspective drawing of the inner side of the deflector according to a first embodiment of the present invention. 
     FIG. 6 is a side view of the tilted deflector according to a first embodiment of the present invention. 
     FIG. 7 is a bottom view of the stator deflector assembly according to a first embodiment of the present invention. 
     FIG. 8 is a perspective view of the stator deflector assembly according to a second embodiment of the present invention. 
     FIG. 9 is a perspective view of the stator deflector assembly according to a first embodiment of the present invention, assembled on a stator. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present invention, as disclosed in the following description, includes a stator deflector assembly, which deflects coolant fluid injected from an electric motor, in particular an electric hybrid motor, onto the stator windings of the motor, in order to cool the stator windings. 
     The stator deflector assembly  10  in a first embodiment, as shown in FIG. 1, includes a perforated plastic stator support module (or deflector)  11  formed to fit the semi-circular design of the stator  24  (see FIG. 9) for an electric motor, and which is enclosed in an absorbent media envelope  12 . The absorbent media envelope  12  is attached to the deflector  11  on an inner side by heat-staked pins  13   a ,  13   b . The heat-staked pins  13   a ,  13   b  ( 13   a  showing after heat-staking, and  13   b  before heat-staking) hold the absorbent media envelope  12  in place on the inner side of the deflector  11 . The absorbent media envelope  12 , has holes  14  through which the coolant (i.e., oil), which is injected from the motor, passes to the windings of the stator  24  to cool the stator  24  (see FIG.  9 ). The absorbent media envelope  12  also soaks up the oil to cool the stator  24 . 
     The other, outer side of the deflector  11 , which is shown in FIG. 2, includes raised protrusions  16  having recesses therein, which protrude through holes  17  (see FIG. 3) in the absorbent media envelope  12 . Cotter pins  15  are inserted through the protrusions  16  to hold the felt media envelope  12  securely on the plastic deflector  11 . However, the cotter pins  15  are optional and need not be included. 
     As shown in FIG. 2, the absorbent media envelope  12  is slitted on the outer side of the deflector  11  in order to more closely adhere to the semi-circular shape of the deflector  11  without ripples being formed in the material of the absorbent media envelope. 
     The absorbent media envelope  12 , as shown in FIG. 3, is a single piece of material which is cut using a cutting die into the appropriate predetermined shape—one example of which is shown in FIG.  3 . The absorbent media envelope  12  must be able to withstand high temperatures due to its placement in the electric motor. The absorbent media envelope  12 , in a preferred embodiment, is made of a layered rolled felt material. 
     The absorbent media envelope  12  is slitted on one side half of the material along its axis of curvature where it is folded in half over the deflector  11 . There are holes  17  in each of the flap portions  18  caused by the slits  19 , such that the protrusions  16  on the deflector  11  can be inserted through the holes  17  and the cotter pins  15  inserted in the protrusions  16 , to hold the absorbent media envelope  12  in place on the deflector  11 . 
     A plurality of holes  14  are disposed on the other side half of the absorbent media envelope  12  opposing the flap portions  18 , such that the coolant can enter the holes  14  to reach the windings of the stator  24 . There are also a plurality of holes  20  disposed at various positions paralleling the axis of curvature of the absorbent media envelope  12 , through which the ends of the heat-staked pins  13   a ,  13   b  on the deflector  11  protrude in order to be heat-staked on the absorbent media envelope  12 . 
     It is apparent that any number of holes  14  for the coolant can be used in the absorbent media envelope  12 , as there can be any number of holes  20  for the heat-staked pins  13   a ,  13   b , and that the positions of those holes  14  and  20  can be at any appropriate location in the absorbent media envelope  12 , as long as they achieve the objective of cooling the stator windings by allowing the coolant to seep therethrough. Further, the slits  18  can be any number of slits, and the holes  17  for the cotter pins  15  can also be of any appropriate number, and are not limited to the seven holes  17  and seven cotter pins  15  shown in FIGS. 2 and 3. Further, the holes  17  and cotter pins  15  can be positioned at any appropriate position. 
     The deflector support module  11  itself is made of injection-molded plastic, the plastic being of any appropriate plastic material which can withstand high temperatures due to its placement in the electric motor. The deflector  11 , as shown on its outer side in FIG. 4, is of a semi-circular shape to match the stator&#39;s curvature. The deflector  11  has raised protrusions  16  on the outer side which are injection-molded with the deflector  11  (see FIG. 6 for a side view of the tilted deflector  11  showing the protrusions  16 ). The cotter pins  15  are placed through these protrusions  16  when the absorbent media envelope is in place (see FIG.  2 ). 
     The deflector  11  also has heat staked-pins  13   b  (see FIG. 1) formed with the deflector  11  by injection-molding, on the inner side of the deflector  11  (see FIG.  5 ). The heat-staked pins  13   a ,  13   b  protrude through the holes  20  in the absorbent media envelope  12  to hold the absorbent media envelope  12  in place against the deflector  11  (see FIG.  2 ). A plurality of holes  21  and slits  22  formed in the deflector  11 , in a major part, substantially align with holes  14  in the absorbent media envelope  12  to allow coolant to enter the assembly  10  and flow over and cool the windings of the stator  24 . 
     It is readily apparent that the deflector  11  can have the protrusions  16 , heat-staked pins  13   b , holes  21 , and slits  22 , disposed at any location, as long as the protrusions  16  and heat-staked pins  13   b  align with the holes  17  and holes  20 , respectively, of the absorbent media envelope  12 . Further, the holes  21  and slits  22  can be disposed at any location in the deflector  11  as long as they substantially allow the coolant to flow over the stator windings after entering through holes  14  of the absorbent media envelope  12 . 
     Once assembled, a wire  23  or other material is passed through the loops at the head of the cotter pins  15  (see FIG.  1 ). When the stator deflector assembly  10  is installed in the automobile housing, the wire  23  is pulled so that the cotter pins  15  are removed, and the absorbent media envelope  12  is released from the surface of the deflector  11  on the outer side of the deflector  11 , and thus, can catch any soak up any coolant fluid and deflect the coolant over the stator windings (see FIG. 9 for the stator deflector assembly  10  assembled on a stator  24 ). 
     The method of assembly of the present invention includes cutting the absorbent media envelope  12  to the appropriate size and predetermined shape, as exemplified in FIG. 3, using a cutting die. The deflector  11  is injection-molded and formed with protrusions  16 , holes  21 , slits  23 , and heat-staked pins  13   b  (see FIG.  1 ). 
     The cut absorbent media envelope  12 , which in the preferred embodiment is a felt material  12 , is then wrapped or folded in half over the deflector  11 . The heat-staked pins  13   b  protrude through the holes  20  in the felt material  12  on the inner side of the module  11  (see FIG.  1 ). The heat-staked pins  13   b  are then heat-staked, such that the protruding pins  13   b  are melted and adhere to the felt  12  (see pins  13   a  in FIG.  1 ), keeping the felt  12  in position on the inner side of the deflector  11  (see FIG.  7 ). 
     The protrusions  16  protrude through the holes  17  of the felt  12  on the outer side of the deflector  11 , and cotter pins  15  are passed through the recesses of the protrusions in order to hold the felt  12  in position against the side surface of the deflector  11 . 
     In a second embodiment of the present invention, no heat-staked pins  13   a ,  13   b  or cotter pins  15  are used, and an adhesive is used to keep the felt in position against the surface of the deflector  11  (see FIG.  8 ). The adhesive need not be liberally applied since some movement of the absorbent media envelope  12  away from the side surface of the deflector  11  on the outer side of the deflector  11  is preferable in order to catch the coolant. Further, in this embodiment, there is also no need to injection-mold the deflector  11  with protrusions  16  or heat-staked pins  13   b , nor is there any need for the plurality of holes  17  and  20  in the absorbent media envelope  12 . 
     Once the stator deflector assembly  10  is assembled as shown in FIGS. 1 and 2, according to the first embodiment, the electric hybrid motor is placed in the housing of the automobile, and the stator deflector assembly  10  is attached through to the motor with conventionally available plastic ratchet pins (see FIG.  9 ). Then, the wire  23  which is passed through the loops at the heads of the cotter pins  15  (see FIG. 1) is pulled, so that the felt  12  is released from the surface of the deflector  11  on the outer side, and thus, can catch and soak up any coolant fluid which is deflected over the stator windings. 
     Although the stator deflector assembly  10  can be used without the wire  23 , it is preferred to use the wire  23  to keep the felt  12  in position against the deflector  11  surface until the stator deflector assembly  10  is in position in the automobile housing. 
     Thus, the stator deflector assembly  10  catches the coolant in the absorbent media envelope  12  as the coolant is injected from the motor over the stator windings (see FIG.  9 ). The coolant is soaked into the absorbent media envelope  12  and seeps through to the deflector  11  inside the stator deflector assembly  10 , successfully soaking the stator windings of the motor. Thus, the task of cooling the stator windings, which ensures that the electric hybrid motor operates within a safe temperature range, is achieved without complexity or substantial costs. 
     The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirits and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.