Coil For An Electric Machine And Method For Producing A Coil

• US 20110127872A1
• Filed: 05/05/2009
• Published: 06/02/2011
• Est. Priority Date: 05/05/2008
• Status: Active Grant

• Current Assignee: Marcus Podack
• Original Assignee: Brose Fahrzeugteile GmbH & Company KG Wã¼Rzburg
• Inventors: Podack, Marcus
• Granted Patent: US 9,035,523 B2
• Time in Patent Office: Days
• US Class Current: 310/180
• CPC Class Codes: H02K 15/0421 consisting of single conductors, e.g. hairpins
• CPC Class Codes: H02K 3/18 Windings for salient poles
• CPC Class Codes: H02K 3/522 for generally annular cores with salient poles
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49071 by winding or coiling

Abstract

The invention relates to a coil (1), in particular for an electric machine, in particular a transformator or an electromechanical converter, in particular an electric motor, for guiding an electric current for producing a magnetic field. Said coil consists of individual windings (2) that are essentially embodied as a flat body thus obtaining a tightly packed structure when the windings (2) are superimposed, and respectively, each winding (2) comprises at least one circulating conductor path with the exception of at least one electric interruption on one side. Said conductor path of a winding (2) comprises, on one point, an electroconductive connection with a conductor path of an adjacent winding (2). The windings (2) are incidentally, essentially electrically isolated to each other.

Claims

1. A coil (1) for an electric machine for conducting an electric current for generating a magnetic field, the coil comprising:

individual turns (2), and the turns (2) are embodied generally as flat bodies, in such a manner that a dense package with turns (2) arranged one on top of the other is obtained, and each turn (2) has at least one circumferential conductor track with the exception of at least one electrical interruption (4) on one side (5), and the conductor track of a turn (2) at one location (6) has an electrically conductive connection (7) to a conductor track of an adjacent turn (2), wherein the turns (2) are, apart from this, substantially electrically insulated from one another.

2. The coil as claimed in claim 1, wherein the interruptions (4) between adjacent turns (2) are arranged offset and/or wherein the electrically conductive connections (7) between adjacent turns (2) are arranged offset, wherein the electrically conductive connection (7) is arranged in the direct vicinity of the interruption (4) of a turn (2).

3. The coil as claimed in claim 1, wherein the interruptions (4) and/or the electrically conductive connections (7) of the turns (2) for each of the successive turns (2) are each arranged offset by a predetermined distance (8) with respect to the connection and/or the interruption of the preceding turn (2).

4. The coil as claimed in claim 1, wherein the interruptions (4) and/or the electrically conductive connections (7) of the turns (2) are arranged on one longitudinal side (11) of the coil (1).

5. The coil as claimed in claim 1, wherein the properties the flat cross sections (9) of the turns (2) are adapted to the respective requirements, and are also embodied in different ways within a coil (1), wherein the turns (2) are embodied as flat bodies of rectangular shape (10).

6. The coil as claimed in claim 1, wherein the turns (2) are punched from a conductive sheet-metal copper strip.

7. The coil as claimed in claim 1, wherein the turns (2), with the exception of the electrically conductive connection (7), are electrically insulated from one another by means of a thin insulating layer (24) made of paper and/or varnish and/or oxide.

8. The coil as claimed in claim 1, wherein the electrically conductive connection (7) between the turns (2) is formed by means of hard soldering and/or mechanical pressure and/or soldering under a protective gas atmosphere or the like.

9. The coil as claimed in claim 1, wherein the coil (1) is constructed and arranged to be assembled outside the electric machine, including the electrically conductive connections (7) between the turns (2), and is to be only subsequently inserted into the electric machine.

10. The coil as claimed in claim 9, wherein after the assembly, the coil is introduced into a stator (12) in such a way that the interruptions (4) and/or the electrically conductive connections (7) are arranged in a groove region (14) of the stator (12).

11. The coil as claimed in claim 1, wherein the interruption (4) is embodied in a way which is adapted in accordance with the electrical requirements.

12. The coil as claimed in claims 1, wherein a contact region (23) for a current connection is provided at at least one end-side turn (2) of the coil (1), wherein the contact region (23) is provided with a solder strip for a soldering process, in particular with a tin layer, and/or wherein, insulation is removed in the contact region (23) and/or wherein the contact region has welding beads or welding bumps for the further formation of electrical contact.

13. The coil as claimed of claim 1, wherein the turns are provided with a corrosion-reducing or corrosion-protection layer.

14. The coil as claimed in claims 1, wherein the two end-side turns each have a contact region, wherein the two contact regions of the end-side turns are arranged at a winding end, and/or in each case a contact region is provided at one of two winding ends lying opposite one another.

15. The coil as claimed in claim 1, wherein before electrical contact is formed, the turns, with the exception of the regions of the electrically conductive connections of the turns to one another, are provided with an adhesive layer for a bonding process which can be activated thermally, wherein the adhesive layer is, thicker than the insulating layer.

17. The stator as claimed in claim 6, wherein the turns of an individual tooth coil (13) are made narrower in the vicinity of a foot region (20) of a tooth (16) than in a shoulder region (21) of a tooth (16).

16. A stator of an electromechanical converter with an internal rotor or external rotor, the stator comprising:

at least one coil having individual turns (2), and the turns (2) are embodied generally as flat bodies, in such a manner that a dense package with turns (2) arranged one on top of the other is obtained, and each turn (2) has at least one circumferential conductor track with the exception of at least one electrical interruption (4) on one side (5), and the conductor track of a turn (2) at one location (6) has an electrically conductive connection (7) to a conductor track of an adjacent turn (2), wherein the turns (2) are, apart from this, substantially electrically insulated from one another, and

a star yoke structure (15),

wherein the coil is fitted onto a tooth (16) of a star (17) in the sense of an individual tooth coil (13).

18. The stator as claimed in claim 16, wherein a plurality of coils are provided with a common contact unit on their contact regions in order to simultaneously make contact with a plurality of coils.

19. A method for producing a coil (1) the method comprising:

providing rectangular flat turns (2), which have an gap-shaped interruption (4) in a longitudinal region (18)

arranging the flat turns (2) one on top of the other and in each case adjacent turns (2) are connected by means of a conductive connection (7) in the longitudinal region (18) using a connecting method,

assembling the coil (1) outside the electric machine, including the electrically conductive connections (7) between the turns (2), and

subsequently inserting the coil (1) into the electric machine.

20. The method as claimed in claim 19, wherein the electrically conductive connections (7) between the turns (2) are formed simultaneously between a plurality of turns or all the turns, by means of hard soldering under a protective gas atmosphere and/or mechanical pressure or the like.

21. The method as claimed in claim 19, wherein a bonding agent which can be activated thermally is used for mechanically securing the turns (2) to one another before the turns are insulated from one another.

22. A method for producing a stator (12) the method comprising:

providing at least one coil having individual turns (2), and the turns (2) are embodied generally as flat bodies, in such a manner that a dense package with turns (2) arranged one on top of the other is obtained, and each turn (2) has at least one circumferential conductor track with the exception of at least one electrical interruption (4) on one side (5), and the conductor track of a turn (2) at one location (6) has an electrically conductive connection (7) to a conductor track of an adjacent turn (2), wherein the turns (2) are, apart from this, substantially electrically insulated from one another, and

providing a star yoke structure (15),

wherein the coil (1) is formed by stacking up individual flat turns (2) outside the stator (12) and is soldered together in order to produce individual, electrically conductive connections (7) in a groove region (14) of the stator (12), and the coil (1) is subsequently fitted as a coil package onto one tooth (16) of a star (17) of a star yoke structure (15), and subsequently after the fitting onto the star (17), the star (17) is inserted into a yoke (19).