COIL ASSEMBLY FOR ROTATING ELECTRIC MACHINE

• US 20100001610A1
• Filed: 08/30/2007
• Published: 01/07/2010
• Est. Priority Date: 08/30/2006
• Status: Active Grant

• Current Assignee: Honda Motor Co., Ltd. (Honda Motor Company)
• Original Assignee: Honda Motor Co., Ltd. (Honda Motor Company)
• Inventors: Ozawa, Masaru, Iki, Tomotaka
• Granted Patent: US 8,148,870 B2
• Time in Patent Office: Days
• US Class Current: 310/208
• CPC Class Codes: H02K 15/0407 Windings manufactured by etching, printing or stamping the complete coil
• CPC Class Codes: H02K 21/24 with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• CPC Class Codes: H02K 3/26 consisting of printed conductors
• CPC Class Codes: H02K 3/47 Air-gap windings, i.e. iron-free windings
• CPC Class Codes: Y10T 29/49012 Rotor
• CPC Class Codes: Y10T 29/4902 Electromagnet, transformer or inductor

Abstract

A coil assembly for a rotating electric machine is a stator coil (201) for use in the stator of a motor (10) or the like, which comprises a coil plate (211) composed of at least two coil plate elements (211-1, 211-2) respectively provided with an internal peripheral portion and an external peripheral portion and having predetermined wiring patterns (241) formed by slits. The coil plate elements are bonded together at their internal peripheral portion and external peripheral portion while leaving the medial portion lying between the internal peripheral portion and the external peripheral portion spaced apart, so as to form the predetermined coil winding patterns (241).

Claims

1. A coil assembly for use in a stator of a rotating electric machine, comprising a coil plate having at least two coil plate elements,

wherein the coil plate elements respectively have an inside peripheral portion and an outside peripheral portion, as well as predetermined wiring patterns formed by slits and are bonded together at the inside peripheral portion and the outside peripheral portion while spaced apart in a medial portion lying between the inside peripheral portion and the outside peripheral portion, so as to provide predetermined coil winding patterns.

2. The coil assembly of claim 1, further comprising an insulating portion which includes at least one of an insulating coating covered by the coil plate elements and an insulating filler material filling gaps between the coil plate elements.

3. The coil assembly of claim 2, wherein the insulating coating material is one selected from the group comprised of polyimide, poly-para-xylene and DLC (diamond-like carbon).

4. The coil assembly of claim 2, wherein the insulating filler material is one selected from the group comprised of a thermosetting resin, a thermoplastic resin and an ultraviolet curing resin.

5. The coil assembly of claim 4, wherein the thermosetting resin, the thermo-plastic resin or the ultraviolet curing resin is one selected from the group comprised of epoxy, phenol, DPA (diallyl phthalate), polyester, polyimide, polyamide, polyamide-imide, PBT (polybutylene terephthalate), PET (polyethylene terephthalate), PPS (polyphenyl sulfide), LCP (liquid crystal polymer) and silicone (silicone resin).

6. The coil assembly of claim 1, wherein the coil plate comprises an annular plate member having an inside peripheral edge insulator and an outside peripheral edge insulator for respectively holding the inside peripheral edge and outside peripheral edge of the coil plate.

7. The coil assembly of claim 1, wherein the coil plate elements are formed by etching of a metal sheet.

8. The coil assembly of claim 1, wherein the coil plate elements are formed by subjecting a metal sheet to electrical discharge machining, wire cutting, laser cutting, or notch pressing.

9. The coil assembly of claim 1, wherein the coil plate elements are formed by stacking and bonding of a predetermined number of thin metal sheets having the slits and the wiring patterns formed thereon by means of etching.

10. The coil assembly of claim 7, wherein the metal sheet and the thin metal sheets are formed of one of copper, copper alloy, aluminum and aluminum alloy.

11. The coil assembly of claim 1, further comprising a current-carrying coil bus bar disposed at the inside peripheral edge of the coil plate.

12. The coil assembly claim 1, wherein the wiring patterns are comprised of a plurality of angled line-shaped coil segments arrayed at equal intervals in a circumferential direction, with the wiring patterns of the opposed different coil plate elements being bonded in a mutually reversed state.

13. The coil assembly of claim 12, wherein the angled line-shaped coil segments are larger in circumferential width at the outside peripheral side than at the inside peripheral side thereof, and circumferential widths of the slits are constant.

14. The coil assembly of claim 12, wherein the slits are larger in circumferential width at the outside peripheral side than at the inside peripheral side thereof, and circumferential widths of the angled line-shaped coil segments are constant.

15. The coil assembly of claim 12, wherein the angled line-shaped coil segments have a center direction straight portion that faces towards a center of the coil plate, diagonal straight portions disposed facing a diagonal direction, and bonded portions at the inside peripheral portion and the outside peripheral portion.

16. The coil assembly of claim 1, wherein the coil wiring patterns are provided with coil loops corresponding in number to n phases that number two or more.

17. The coil assembly of claim 16, wherein a phase angle range respectively occupied in the circumferential direction by the coil loops is 1/n of a pole spacing pitch of magnets arrayed in the circumferential direction in correspondence with the coil plate.

18. The coil assembly of claim 16, wherein the coil loops include first and second coil loop elements of identical shape, with the first and second coil loop elements disposed so as to have a circumferential direction phase difference equivalent to the pole spacing pitch.

19. The coil assembly of claim 18, wherein the first and second coil loop elements each have a wave winding-shaped configuration, circulating electrical current flows in mutually opposite directions through the first and second coil loop elements, and the center direction straight portions disposed facing towards the center of the coil plate in the angled line-shaped coil segments comprised of the first and second coil loop elements are positioned in mutual opposition so that electrical current flows in the same direction therethrough.

20. The coil assembly of claim 1, wherein the at least two coil plate elements are bonded together by means of diffusion bonding, thermo-compression bonding, or brazing.

21. The coil assembly of claim 1, wherein a ceramic sheet is disposed in the gap between the at least two coil plate elements.

22. The coil assembly of claim 1, wherein a ceramic spray coating is applied to each of the at least two coil plate elements such that the coating faces the gap therebetween.

23. A rotating electric machine comprising:

a stator equipped with at lease one coil assembly; and

a rotor,

wherein the coil assembly is comprised of a coil plate having at least two coil plate elements, and the coil plate elements are each provided with an inside peripheral portion and an outside peripheral portion and have predetermined wiring patterns formed by slits and are bonded together at the inside peripheral portion and the outside peripheral portion while spaced apart in a medial portion lying between the inside peripheral portion and the outside peripheral portion, so as to provided predetermined coil winding patterns.

24. The rotating electric machine of claim 23, wherein the rotor is positioned on one or both sides of the stator so that the machine has an axially-gapped disk form.

25. The rotating electric machine of claim 24, wherein a shared shaft-shaped center portion is provided to a center portion of the stator and a center portion of the rotor;

and at least one of a cooling system and a power supply system is disposed in a centralized arrangement in the shaft-shaped center portion.

26. The rotating electric machine of claim 23, wherein it comprises an in-wheel motor incorporated into a vehicle wheel and providing rotary drive of the vehicle wheel.

27. A method of manufacturing a coil assembly for use in a stator of a rotating electric machine, the method comprising the steps of:

forming a coil plate composed of at least two coil plate elements that are respectively provided with an inside peripheral portion and an outside peripheral portion and have predetermined wiring patterns formed by slits; and

bonding together the coil plate elements at the inside peripheral portion and the outside peripheral portion while leaving a medial portion lying between the inside peripheral portion and the outside peripheral portion spaced apart, so as to provide predetermined coil winding patterns.

28. The method of claim 27, further comprising the step of forming an insulating portion that includes at least one of an insulating coating for covering the coil plate elements, and an insulating filler material for filling gaps between the coil plate elements.

29. The method of claim 28, wherein the insulating coating material is one selected from the group comprised of polyimide, poly-para-xylene and DLC (diamond-like carbon).

30. The method of claim 28, wherein the insulating filler material is one selected from the group comprised of a thermosetting resin, a thermoplastic resin, and an ultraviolet curing resin.

31. The method of claim 30, wherein the thermosetting resin, the thermoplastic resin, or the ultraviolet curing resin is one selected from the group comprised of epoxy, phenol, DPA (diallyl phthalate), polyester, polyimide, polyamide, polyamide-imide, PBT (polybutylene terephthalate), PET (polyethylene terephthalate), PPS (polyphenyl sulfide), LCP (liquid crystal polymer) and silicone (silicone resin).

32. The method of claim 27, wherein the step of forming the coil plate includes forming the coil plate as an annular plate member;

and the step of forming the coil plate further includes the step of attaching an inside peripheral edge insulator and an outside peripheral edge insulator for respectively holding the inside peripheral edge and outside peripheral edge of the coil plate.

33. The method of claim 27, wherein the step of forming the coil plate elements comprises the step of forming the coil plate elements by etching of a metal sheet.

34. The method of claim 27, wherein the step of forming the coil plate elements comprises the step of forming the coil plate elements by subjecting a metal sheet to one of electrical discharge machining, wire cutting, laser cutting and notch pressing.

35. The method of claim 27, wherein the step of forming the coil plate elements includes the steps of:

forming the slits and the wiring patterns on thin metal sheets by means of etching; and

stacking and bonding of a predetermined number of the thin metal sheets.

36. The method of claim 33, wherein the metal sheet and the thin metal sheets are formed of one of copper, copper alloy, aluminum and aluminum alloy.

37. The method of claim 27, further comprising the step of providing a current-carrying coil bus bar at the inside peripheral edge of the coil plate.

38. The method of claim 27, wherein the step of forming the coil plate comprises the step of bonding together the at least two coil plate elements by means of diffusion bonding, thermocompression bonding, or brazing.

39. The method of claim 27, wherein the step of forming the coil plate comprises the step of providing a ceramic sheet in the gap between the at least two coil plate elements.

40. The method of claim 27, further comprising the step of providing a ceramic spray coating on each of the at least two coil plate elements such that the coating faces the gap therebetween.

41. A method of manufacturing a rotating electric machine, comprising the steps of:

manufacturing a stator;

manufacturing a rotor; and

assembling the stator and the rotor,

wherein the stator manufacturing step includes the steps of;

forming a coil plate comprised of at least two coil plate elements respectively provided with an inside peripheral portion and an outside peripheral portion and having predetermined wiring patterns formed by slits; and

bonding together the coil plate elements at the inside peripheral portion and the outside peripheral portion while leaving a medial portion lying between the inside peripheral portion and the outside peripheral portion spaced apart, so as to provided the predetermined coil winding patterns.

42. The method of claim 41, wherein the step of assembling the stator and the rotor comprises the step of positioning the rotor on one or both sides of the stator so that the rotating electric machine has an axial disk type overall structure.