Method for forming coils of motor rotors

Abstract

In a method for forming the coils passed through the core slots of a motor rotor so as to keep the coils fully received in the core slots, a motor rotor, in which coils are wound around the core thereof, is received in a metallic mold die which has a die surface spaced from the outer circumferential surface of the core by a certain gap, and resin material is injected from an injection inlet provided in an axial end of the upper metallic mold die. As the resin material is injected into the cavity of the metallic mold die, the resin material first fills the gap, and then flows into the core slots from the outer periphery thereof. The flow and the pressure of the resin material causes the coils to be pushed toward the bottom regions of the core slots, and once the filled resin material is cured, the coils are firmly secured well inside the core slots. Thereby, the cost of the component parts is reduced, and the fabrication process in forming coils of motor rotors is simplified, in contrast to the conventional method which uses wedges to retain the coils in the core slots.