High fill stator design

• US 6,278,213 B1
• Filed: 01/13/2000
• Issued: 08/21/2001
• Est. Priority Date: 01/13/2000
• Status: Expired due to Term

• Current Assignee: BorgWarner Incorporated
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Bradfield, Michael Duane
• Primary Examiner(s): NGUYEN, TRAN N
• Application Number:
  US09/482,234
• Time in Patent Office: 586 Days
• Field of Search: 310/216, 310/201, 310/261, 295/96--98
• US Class Current: 310/216.069
• CPC Class Codes: H02K 1/165 Shape, form or location of the slots
• CPC Class Codes: H02K 3/48 in slots

Abstract

A high fill rigid stator winding and core design for use in generators. The stator design consists of a plurality of stator teeth with slots between the teeth. Flattened magnet wire with rounded edges is stacked in the slots. The slots are angled slightly to produce a wedging effect to keep the wire in the slots.

Claims

1. A stator for an electrical machine comprising:

a yoke;

a plurality of teeth wherein each tooth being configure without a circumferential-extended tooth tip; and

a plurality of slots;

said slots formed by pairs of adjacent teeth, each slot having a top adjacent to said yoke, two sides, and an open bottom, a plurality of said slots in which said sides of said slots are at an angle to each other, said open bottom having a width selected to admit only one substantially flattened stator conducting wire therethrough, said width of said bottom being substantially the same as the width of the slot.

2. The stator of claim 1 wherein all slots have the same shape.

3. The stator of claim 1 further comprising a slot liner in each slot.

4. The stator of claim 1 wherein said slots contain a portion of a stator winding.

5. The stator of claim 1 wherein the width of each slot is selected so as to contain only one stator winding conductor.

6. The stator of claim 1 wherein said angle is two degrees.

7. The stator of claim 1 further comprising flattened conducting wire in said slots.

8. The stator of claim 1 further comprising stacked non-circular conducting wire in said slots.

9. An alternating current generator comprising a stator assembly having a stator winding comprising winding layers with conducting wires, the stator having a stator core comprising:

a yoke;

a plurality of teeth wherein each tooth being configure without a circumferential-extended tooth tip;

a plurality of slots, each slot located between adjacent teeth and each slot having a top adjacent to the yoke, two sides, and an open bottom;

wherein the sides of the slots are not parallel so that the top of each slot is wider than the bottom of the slot said open bottom having a width selected to admit only one substantially flattened conducting wire, said width of said bottom being substantially the same as the width of the slot.

10. The generator of claim 9 further comprising a stator winding held in place within said slots due to a wedging action caused by the sides of the slot.

11. The generator of claim 10 further comprising a stator winding having a plurality of layers of conducting wires and wherein the width of said slots is such that only one stator winding conducting wire can fit within the slot per winding layer.

12. The generator of claim 10 further comprising a stator winding having a plurality of layers of conducting wires wherein said wires are stacked.

13. The generator of claim 10 further comprising a stator winding having a plurality of layers of conducting wires wherein said wires are flattened.

14. The generator of claim 10 further comprising a stator winding having a plurality of layers of conducting wires wherein said wires are noncircular in cross section.