Patent ID: 11502588

Abstract:
A method for manufacturing a polymeric electrical machine includes manufacturing a stator including a laminated stator core and a plurality of windings including winding overhangs; applying a surface treatment to the stator core constructed to reduce defects at an interface between a polymeric material and the stator core and enhance adherence between the polymeric material and the stator core; mounting the stator onto a mandrel; inserting the stator into an electrical machine housing mold; molding an electrical machine housing including a stator band with an integral non-drive end endplate, including overmolding the stator and winding overhangs within the stator band; molding a drive end endplate, including forming polymeric ribs in the drive end endplate and overmolding a metallic structure into the endplate, the metallic structure enhancing mechanical stiffness of the endplate; installing a rotor assembly into the electrical machine housing; and installing the endplate onto the electrical machine housing.