Coil module for a stator of an electric motor, stator, electric motor, circulation pump and method of manufacturing a stator

• US 20090146524A1
• Filed: 12/01/2008
• Published: 06/11/2009
• Est. Priority Date: 06/02/2006
• Status: Active Grant

• Current Assignee: ITT Manufacturing Enterprises, Inc. (ITT, Inc.)
• Original Assignee: Birger Laing, Karsten Laing, Oliver Laing
• Inventors: Laing, Karsten
• Granted Patent: US 7,759,836 B2
• Time in Patent Office: Days
• US Class Current: 310/208
• CPC Class Codes: H02K 3/522 for generally annular cores with salient poles
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine

Abstract

A coil module for a stator of an electric motor comprising a coil holder, a coil that is disposed on the coil holder, a first web and a second web is provided, wherein situated between the first web and the second web are a first coil portion and a second coil portion for contacting with a motor circuit.

Claims

1. Coil module for a stator of an electric motor, comprising:

a coil holder;

a coil that is disposed on the coil holder;

a first web and a second web;

wherein situated between the first web and the second web are a first coil portion and a second coil portion for contacting with a motor circuit.

2. Coil module according to claim 1, wherein the coil is wound on the coil holder.

3. Coil module according to claim 1, wherein the coil holder is designed in such a way that the coil can be manufactured on the coil holder by means of a winding machine.

4. Coil module according to claim 1, wherein the first coil portion lies in the region of a first wire end of the coil.

5. Coil module according to claim 1, wherein the second coil portion lies in the region of a second wire end of the coil.

6. Coil module according to claim 1, wherein at least one of the first coil portion and the second coil portion is fastened to at least one of the first web and second web by means of winding.

7. Coil module according to claim 6, wherein at least one of the first web and the second web have at least one recess for receiving a winding.

8. Coil module according to claim 1, wherein the first web and the second web lie substantially parallel to one another.

9. Coil module according to claim 1, wherein the first coil portion and the second coil portion lie transversely of the first web and the second web.

10. Coil module according to claim 1, wherein the first coil portion and the second coil portion lie transversely of a coil axis.

11. Coil module according to claim 1, wherein the first web and the second web are oriented transversely of a coil axis.

12. Coil module according to claim 1, wherein the first web and the second web differ in length.

13. Coil module according to claim 1, wherein the first coil portion and the second coil portion lie at an angle to one another.

14. Coil module according to claim 1, wherein the first coil portion and the second coil portion are electrically contactable from above with contact points.

15. Coil module according to claim 1, wherein the coil holder is designed in such a way that it is mountable onto a coil holder receiver of the stator.

16. Coil module according to claim 1, wherein the coil holder has a recess, into which a locating pin can be introduced.

17. Coil module according to claim 1, wherein the coil holder comprises a base element and a top element, which overlap the coil.

18. Coil module according to claim 17, wherein the first web and the second web are disposed on the base element.

19. Coil module according to claim 18, wherein there is disposed on the base element a flange, which has a direction of extent parallel to a coil axis and on which the first web and the second web are seated.

20. Coil module according to claim 1, wherein an anti-rotation device for the rotational fixing on the stator is provided.

21. Coil module according to claim 20, wherein the anti-rotation device is formed by means of at least on of at least (i) one pin and (ii) one pin receiver.

22. Coil module according to claim 1, wherein the first web and the second web are seated integrally on the coil holder.

23. Coil module according to claim 1, wherein the coil holder is manufactured from a plastics material.

24. Coil module according to claim 1, wherein the coil holder has a winding core, which is of a cylindrical construction.

25. Stator for an electric motor, comprising:

a magnetic return body, on which at least one coil module is disposed, said coil module comprising;

a coil holder;

a coil that is disposed on the coil holder;

a first web and a second web;

wherein situated between the first web and the second web are a first coil portion and a second coil portion for contacting with a motor circuit.

26. Stator according to claim 25, wherein the first coil portion and the second coil portion are electrically connected to respective contact points.

27. Stator according to claim 26, wherein the first coil portion and the second coil portion are connected to respective contact points by welding or soldering.

28. Stator according to claim 26, wherein the contact points are disposed on a printed circuit board.

29. Stator according to claim 28, wherein the printed circuit board is disposed below the magnetic return body.

30. Stator according to claim 28, wherein the printed circuit board has, associated with the at least one coil module, at least one pin receiver and/or at least one pin for forming an anti-rotation device, wherein at least one pin of the coil module is introduced into the at least one pin receiver and/or the at least one pin of the printed circuit board is introduced into at least one pin receiver of the coil module.

31. Stator according to claim 25, wherein the magnetic return body has at least one locating pin, on which the at least one coil module is disposed.

32. Stator according to claim 31, wherein the magnetic return body has a plurality of locating pins, which are arranged distributed around an axis.

33. Stator according to claim 31, wherein the at least one locating pin comprises a first region, on which the associated coil module is seated, and a second region, which lies outside the coil module.

34. Stator according to claim 33, wherein a plurality of locating pins are provided, the second regions of which have as a common surface envelope a spherical surface segment.

35. Stator according to claim 31, wherein the magnetic return body has a holding base, on which the at least one locating pin is disposed.

36. Stator according to claim 35, wherein the holding base and the at least one locating pin are integrally connected to one another.

37. Stator according to claim 25, wherein the magnetic return body is manufactured from a compressed powder material.

38. Stator according to claim 37, wherein the powder material comprises iron grains that are electrically isolated from one another.

39. Stator according to claim 35, wherein the holding base has a recess, in which lie the first web and the second web of the at least one coil module.

40. Stator according to claim 35, wherein the holding base takes the form of a ring.

41. Electric motor, comprising:

a rotor; and

a stator, said stator comprising a magnetic return body, on which a plurality of coil modules are disposed, said coil modules comprising;

a coil holder;

a coil that is disposed on the coil holder;

a first web and a second web;

wherein situated between the first web and the second web are a first coil portion and a second coil portion for contacting with a motor circuit.

42. Electric motor according to claim 41, wherein the rotor by means of one or more permanent magnets is a magnetic field-generating rotor.

43. Electric motor according to claim 41, wherein the rotor is positioned above the coils.

44. Electric motor according to claim 41, wherein the rotor is spherically mounted.

45. Electric motor according to claim 41, wherein the stator is of a spherical design at least in segments facing the rotor.

46. Electric motor according to claim 45, wherein one or more pole shoes are disposed on a top on the stator.

47. Electric motor according to claim 45, wherein the rotor is of a spherical design facing a spherical region of the stator.

48. Circulation pump, which has an electric motor, comprising:

a rotor; and

a stator, said stator comprising a magnetic return body, on which a plurality of coil modules are disposed, said coil modules comprising;

a coil holder;

a coil that is disposed on the coil holder;

a first web and a second web;

wherein situated between the first web and the second web are a first coil portion and a second coil portion for contacting with a motor circuit.

49. Method of manufacturing a stator, in which at least one coil module is manufactured, said coil module comprising:

a coil holder;

a coil that is disposed on the coil holder;

a first web and a second web;

wherein situated between the first web and the second web are a first coil portion and a second coil portion for contacting with a motor circuit, said method comprising the further steps;

disposing the at least one coil module on a magnetic return body; and

welding or soldering the first coil portion and the second coil portion to contact points of a printed circuit board that is associated with the stator.

50. Method according to claim 49, wherein the welding is effected by means of a robot.

51. Method according to claim 49, wherein the manufacture of a coil on the at least one coil module is effected by means of a winding machine.