Patent ID: 8575796

Claim:
A heavy duty stator core and coil assembly that can accommodate severe input voltage spiking comprising: a core made up of a plurality of stacked laminations, said core being substantially cylindrical in shape and having a central bore and a plurality of longitudinally extending slots formed in an exterior surface thereof; a plurality of elongate slot liners, said slot liners arranged in nested pairs and each of said nested pairs being positioned in a different one of said slots; and a plurality of coils of conductive wire being positioned in said slots and spaced from said core by said nested pairs of said slot liners; wherein each of said laminations is made by a process including a step of first annealing said lamination, then coating a side of said lamination by spraying with a rust and corrosion inhibitor, whereby eddy current losses between said laminations is reduced; a coat of varnish covering said exterior surface of said stator core and coil assembly, wherein said coat of varnish is applied to said stator core and coil assembly by the steps of (a) dipping said stator core and coil assembly vertically downwardly end-first along a longitudinal axis thereof into a first tank having a liquid epoxy resin of a relatively low viscosity and removing said stator core and coil assembly therefrom such that said stator coil is coated with a first, relatively thin coat of epoxy resin; (b) allowing said first coat to dry; (c) dipping said stator core and coil assembly end-first along a longitudinal axis thereof into a second tank having a liquid epoxy resin of a relatively high viscosity and removing said stator therefrom such that said stator coil is coated with a second, relatively thin coat of epoxy resin; and (d) allowing said second coat to dry.