Coil mold piece, manufacturing method thereof, core, manufacturing method thereof, and rotating machine

• US 20030127933A1
• Filed: 02/12/2003
• Published: 07/10/2003
• Est. Priority Date: 02/27/1998
• Status: Abandoned Application

• Current Assignee: Masaharu Senoh, Noriaki Yamamoto, Suetaro Shibukawa, Yuji Enomoto, Yukinori Taneda
• Original Assignee: Masaharu Senoh, Noriaki Yamamoto, Suetaro Shibukawa, Yuji Enomoto, Yukinori Taneda
• Inventors: Enomoto, Yuji, Yamamoto, Noriaki, Shibukawa, Suetaro, Taneda, Yukinori, Senoh, Masaharu
• Application Number:
  US10/364,363
• Publication Number:
  US 20030127933A1
• Time in Patent Office: Days
• US Class Current: 310/194
• CPC Class Codes: C07D 493/04 Ortho-condensed systems
• CPC Class Codes: H02K 1/148 Sectional cores H02K1/141 takes precedence
• CPC Class Codes: H02K 1/185 to outer stators
• CPC Class Codes: H02K 15/022 with salient poles or claw-shaped poles

Abstract

To provide a technology for increasing the utilization rate of the iron core material in the stator of a rotating machine and a technology to improve the space factor of the stator winding in a rotating machine. A stator is formed from a core 2 for a rotating machine comprised of a coreback 22 and a plurality of teeth 21, and a coil mold piece 1 mounted in each of said teeth 21. The coreback 22 and a plurality of teeth 21 are mounted in a separate piece, a link 213 for the teeth 21 is fit onto the corresponding teeth link 221 of the coreback 22 in order to link the coreback 22 and the teeth 21. A coil mold piece is adapted for use in a rotating electric machine, wherein the coil mold piece is compacted-shaped such that a substantial majority of wire windings are plastically deformed to minimize spacings between the wire windings, and such that at least one predetermined cross-section across the coil mold piece has a predetermined wedge shape. The wire material of the coil mold piece 1 contains through holes 1a and is formed while wound in a ring shape. The through holes 1a has a cross-sectional shape to allow fitting onto the teeth.

Claims

1. A coil mold piece adapted for use in a rotating electric machine, wherein said coil mold piece is compacted-shaped such that a substantial majority of wire windings are plastically deformed to minimize spacings between said wire windings, and such that at least one predetermined cross-section across said coil mold piece has a predetermined wedge shape.

2. A coil mold piece as claimed in claim 1, wherein said coil mold piece is adapted to have a through-hole to facilitate mounting of said coil mold piece onto a core tooth and within a core slot of said rotating electric machine, wherein a side surface of said wedge shape is adapted to be stored in said slot and spread out in a fan-shape from one end of said through-hole towards another end, and said one end being adapted to adjoin a tip of said tooth, and said another end being adapted to adjoin a coreback of said rotating electric machine.

3. A coil mold piece as claimed in claim 1, wherein said coil mold piece is compacted-shaped into said predetermined wedge shape by at least one of a press mold apparatus and a stamper apparatus.

4. A coil mold piece as claimed in claim 1, wherein said one end being adapted to adjoin said tip of said tooth is formed at an angle which is oblique to an central axis of said through-hole.

5. A coil mold piece as claimed in claim 1, wherein with a diameter of a wire material of said coil mold piece being given as d, with windings aligned radially along a coil mold piece being given as m, with a number of wire layers aligned tangentially across a coil mold piece being given as n, and with said wire material well aligned in said slot, a surface area S₀ for a particular cross-section of said coil mold piece is expressed as:

S₀={d+{square root}{square root over (3)}·

d/2·

(n−

1)}·

(d·

m)

so that the cross-sectional area Sp for the portion stored in said slot for a cross-section of the same section is S_p<

S₀.

6. A stator adapted for use in a rotating electric machine, said stator comprising:

a core; and

at least one coil mold piece, wherein said coil mold piece is compacted-shaped such that a substantial majority of wire windings are plastically deformed to minimize spacings between said wire windings, and such that at least one predetermined cross-section across said coil mold piece has a predetermined wedge shape.

7. A stator as claimed in claim 6:

wherein said core comprises a coreback, at least one core tooth and a core slot; and

wherein said at least one coil mold piece has a through-hole mounting said coil mold piece onto said at least one core tooth, and being mounted within said core slot, wherein a side surface of said wedge shape is stored in said core slot and spread out in a fan-shape from one end of said through-hole towards another end, and said one end adjoining a tip of said at least one tooth, and said another end adjoining said coreback.

8. A stator as claimed in claim 6, wherein said coil mold piece is compacted-shaped into said predetermined wedge shape by at least one of a press mold apparatus and a stamper apparatus.

9. A stator as claimed in claim 6, wherein said one end adjoining said tip of said core tooth is formed at an angle which is oblique to an central axis of said through-hole.

10. A stator as claimed in claim 6, wherein with a diameter of a wire material of said coil mold piece being given as d, with windings aligned radially along a coil mold piece being given as m, with a number of wire layers aligned tangentially across a coil mold piece being given as n, and with said wire material well aligned in said slot, a surface area S₀ for a particular cross-section of said coil mold piece is expressed as:

S₀={d+{square root}{square root over (3)}·

d/2·

(n−

1)}·

(d·

m)

so that the cross-sectional area S_p for the portion stored in said slot for a cross-section of the same section is S_p<

S₀.

11. A stator as claimed in claim 7;

wherein said coreback is constructed of a plurality of multiple-sector coreback strips laminated together;

wherein said core includes a predetermined plurality of core teeth, and said teeth are provided as one of;

individual teeth of a laminated construction; and

, linked teeth of a laminated construction; and

wherein said coreback and said teeth interconnect using a predetermined interconnection arrangement.

12. A stator as claimed in claim 11, wherein said at least one coil mold piece is adapted to be mounted onto said teeth before interconnection of said coreback and said teeth.

13. A stator as claimed in claim 11;

wherein said predetermined plurality of core teeth are linked teeth of a laminated construction; and

wherein said multiple-sector coreback strips and said linked teeth are at least one of stamped and cut from a strip-like metal stock.

14. A method of manufacturing a coil mold piece adapted for use in a rotating electric machine, said method comprising compact-shaping said coil mold piece such that a substantial majority of wire windings are plastically deformed to minimize spacings between said wire windings, and such that at least one predetermined cross-section across said coil mold piece has a predetermined wedge shape.

15. A method as claimed in claim 14, wherein said coil mold piece is adapted to have a through-hole to facilitate mounting of said coil mold piece onto a core tooth and within a core slot of said rotating electric machine, wherein a side surface of said wedge shape is adapted to be stored in said slot and spread out in a fan-shape from one end of said through-hole towards another end, and said one end being adapted to adjoin a tip of said tooth, and said another end being adapted to adjoin a coreback of said rotating electric machine.

16. A method as claimed in claim 14, wherein said coil mold piece is compacted-shaped into said predetermined wedge shape by at least one of a press mold apparatus and a stamper apparatus.

17. A method as claimed in claim 14, wherein said one end being adapted to adjoin said tip of said tooth is formed at an angle which is oblique to an central axis of said through-hole.

18. A method as claimed in claim 14, wherein with a diameter of a wire material of said coil mold piece being given as d, with windings aligned radially along a coil mold piece being given as m, with a number of wire layers aligned tangentially across a coil mold piece being given as n, and with said wire material well aligned in said slot, a surface area S₀ for a particular cross-section of said coil mold piece is formed in such a manner so as to expressed as:

S₀={d+{square root}{square root over (3)}·

d/2·

(n−

1)}·

(d·

m)

so that the cross-sectional area S_p for the portion stored in said slot for a cross-section of the same section is S_p<

S₀.

19. A method of manufacturing a stator adapted for use in a rotating electric machine, said method comprising;

forming a stator comprising a core; and

compact-shaping at least one coil mold piece such that a substantial majority of wire windings are plastically deformed to minimize spacings between said wire windings, and such that at least one predetermined cross-section across said coil mold piece has a predetermined wedge shape.

20. A method as claimed in claim 19:

wherein said core comprises a coreback, at least one core tooth and a core slot; and

wherein said at least one coil mold piece has a through-hole;

and further comprising mounting said coil mold piece onto said at least one core tooth and within said core slot, wherein a side surface of said wedge shape is stored in said core slot and spread out in a fan-shape from one end of said through-hole towards another end, and said one end adjoining a tip of said at least one tooth, and said another end adjoining said coreback.

21. A method as claimed in claim 19, wherein said coil mold piece is compacted-shaped into said predetermined wedge shape by at least one of a press mold apparatus and a stamper apparatus.

22. A method as claimed in claim 19, wherein said one end adjoining said tip of said core tooth is formed at an angle which is oblique to an central axis of said through-hole.

23. A method as claimed in claim 19, wherein with a diameter of a wire material of said coil mold piece being given as d, with windings aligned radially along a coil mold piece being given as m, with a number of wire layers aligned tangentially across a coil mold piece being given as n, and with said wire material well aligned in said slot, said coil mold piece is formed such that a surface area S₀ for a particular cross-section of said coil mold piece is expressed as:

S₀={d+{square root}{square root over (3)}·

d/2·

(n−

1)}·

(d·

m)

so that the cross-sectional area S_p for the portion stored in said slot for a cross-section of the same section is S_p<

S₀.

24. A method as claimed in claim 20;

wherein said coreback is constructed of a plurality of multiple-sector coreback strips laminated together;

wherein said core includes a predetermined plurality of core teeth, and said teeth are provided as one of;

individual teeth of a laminated construction; and

, linked teeth of a laminated construction; and

further comprising interconnecting said coreback and said teeth using a predetermined interconnection arrangement.

25. A method as claimed in claim 24, wherein said at least one coil mold piece is mounted onto said teeth before interconnecting of said coreback and said teeth.

26. A method as claimed in claim 24;

wherein said predetermined plurality of core teeth are linked teeth of a laminated construction; and

wherein said multiple-sector coreback strips and said linked teeth are at least one of stamped and cut from a strip-like metal stock.