Yasa Limited

Mark Stephen Ewart East

Andrew Court

Jonathan James Biddulph

Charles Edmund King

Timothy Woolmer

Christopher Thomas McCaw

Jon Barker

Andrew Lee Court

Timothy James Thursby Woolmer

Sophie Ann Parker

We describe a method of manufacturing a stator of an axial flux permanent magnet machine, the machine having a stator comprising a stator housing defining a chamber 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: providing first and second radial walls for said stator housing; providing inner and outer side walls for said stator housing; assembling said first and second radial walls and said inner and outer side walls around said set of coils to form a stator assembly, wherein said assembling further comprises: providing one or more collapsible elements between said side walls and one or both of said first and second radial walls; and attaching said side walls to said first and second radial walls, wherein said attaching comprises controlling one or both of a spacing and a degree of parallelism of said first and second radial walls by controlling the collapse of said one or more collapsible elements.

Axial flux machine manufacture

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

Growing community of inventors

Hungerford, United Kingdom

Mark Stephen Ewart East