Yasa Limited

Yasa Motors Limited

Jon Barker

Charles Edmund King

Andrew Court

Tim Woolmer

Timothy Woolmer

Jonathan James Biddulph

Mark Stephen Ewart East

Andrew Lee Court

Mark East

Chris Gardner

Timothy James Thursby Woolmer

We describe a method of manufacturing a housing for the stator of an axial flux permanent magnet machine, the machine having a stator comprising a set of coils wound on respective stator bars and disposed circumferentially at intervals about an axis of the machine, and a rotor bearing a set of permanent magnets and mounted for rotation about said axis, and wherein said rotor and stator are spaced apart along said axis to define a gap therebetween in which magnetic flux in the machine is generally in an axial direction, the method comprising: fabricating a radial wall for said stator housing to be located in said gap between said rotor and said stator by: placing a resin membrane into a mold of an injection molding machine; injection molding a set of reinforcing features onto said membrane using a thermoplastic polymer bondable when molten with said resin; and manufacturing said housing using said radial wall.

Stator-plate overmoulding

There is provided an axial flux motor comprising one or more rotating disks () and a stator () comprising a cavity () formed between walls () and containing therein more than one electro-magnetic coil assembly (). Each electro-magnetic coil assembly () comprises more than one pole piece (), each having an axially extending shank portion () and first and second radially extending end shoes () and one or more associated coils (), each of the one or more associated coils () being wound around a shank portion (), wherein said outer surface () of said end shoes are preferably joined to one or other of said walls (). One or both of said first or second shoes further comprise a heat exchange surface () facing a coil () wound around the shank () such as to define first cooling channels () between one or both of said heat exchange surface () and said coil (), and a second flow channel () defined by the spacing of said coil () and adjacent coils ().

Pole shoe cooling gap for axial motor

An electric machine () comprises a rotor () having permanent magnets () and a stator () having coils () wound on stator bars () for interaction with the magnets across an air gap () defined between them. The bars () and coils () are enclosed by an annular stator housing () that extends between the air gap. A chamber () is defined that incorporates cooling medium to cool the coils. The stator housing comprises two mating clamshells () that mount the stator bars and coils in the machine. Each clamshell is molded from reinforced plastics and interconnected (optionally through one or more intermediate components). At least one clamshell has over-molded therein stator bar shoes that form part of said radial wall, and optionally one or more of the following components: cylindrical boss supports extending along the cylindrical outer wall part; connection studs that communicate electrically the chamber externally; stator coils; coolant inlet and outlet ports; and an outer race of a rotor bearing.

Electric machine&#x2014;over-moulding construction

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Oxford, United Kingdom

Jon Barker