Patent ID: 7913375

Claim:
A method of manufacturing a preliminary made insertable winding for stators with slots comprising the combination of steps: a. Manufacturing a metal mandrel generally of a cylindrical shape with a step for the low end-winding and optionally a slight taper in the direction of extraction and slots for installation of teeth; b. Installing a ring with turning pins on the top end-winding region of said mandrel and providing a gap for a compacting bandage between teeth and turning pins; c. Installing retractable metal teeth on the mandrel in corresponding slots wherein teeth should hang over the low end-winding region of the mandrel the teeth should have rounded edges sufficient for avoiding any damage to insulation of the wire; d. Installing side rings on said mandrel; e. Treating teeth, mandrel and side rings by release agent in order to facilitate extraction of the winding; f. Introducing a layer of insulation is introduced on the mandrel by pouring thermally conductive compound on the turning mandrel; the mandrel has to turn horizontally making a few turns in one direction and then a few turns in another direction in order to keep compound on the mandrel and have a uniform insulation layer on the operating region of the mandrel and teeth; after that curing must be performed while the mandrel keeps turning; g. Pouring thermally conducting compound on the mandrel comprising polymer and powder of non-conducting material; h. Fixation and insulation of the first end wire for each new coil; i. Manufacturing coils using insulated magnet wire with the wire going under the teeth in the low end-winding region; j. Fixation and insulation of the second end wire for a completed coil; k. Repeating steps g.-j. for each new coil; l. Manufacturing and/or installing interlayer insulation upon each completed winding layer; m. Winding a compacting bandage on the top end-winding region between teeth and turning pins upon completing each new winding layer; n. Repeating steps g.-m. for each new winding layer; o. Compacting and compressing the winding using a combination of the outer shell and side rings; p. Curing the winding; q. Removing side rings and extracting the winding from the mandrel; r. Removing teeth from the winding; s. Installing the winding into the stator.