Automotive alternator stator assembly with varying end loop height between layers
First Claim
1. A stator core assembly for an automotive alternator of the type having a rotor assembly and a stator assembly, said stator assembly of the type having at least one phase and having an annular core defining an outside diameter, an inside diameter, and a plurality of radially projecting winding slots opening to said inside diameter but terminating short of said outside diameter, said stator core assembly comprising:
- a first continuous electrical conductor;
a plurality of layers, N, each of said layers being defined by one substantially complete circumferential pass of said conductor around said stator core;
said conductor including a plurality of straight portions that lay within said predetermined radially projecting winding slots, and a plurality of end loop portions that extend circumferentially to connect two of said straight portions, wherein the length of said end loop portions varies based upon the radial location of said particular layer within said stator core and the end loop axial height varies between radial positions within said stator core based upon the radial location of a particular layer within said stator core.
18 Assignments
0 Petitions
Accused Products
Abstract
A stator core assembly having an annular core defining an outside diameter, an inside diameter, and a plurality of radially projecting winding slots. A first electrical conductor and a second continuous electrical conductor are inserted within the winding slots circumferentially around the stator core. The conductors form a plurality of layers, each layer being defined as one substantially complete circumferential pass of the conductors around the stator core. Each of the conductors include a plurality of straight portions that lay within the winding slots, and a plurality of end loop portions that extend circumferentially to connect two of the straight portions. The length of the straight portions and end loop portions vary between the layers based upon the radial location of the particular layer within the stator core and a pre-determined axial height of the end loop portions.
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Citations
27 Claims
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1. A stator core assembly for an automotive alternator of the type having a rotor assembly and a stator assembly, said stator assembly of the type having at least one phase and having an annular core defining an outside diameter, an inside diameter, and a plurality of radially projecting winding slots opening to said inside diameter but terminating short of said outside diameter, said stator core assembly comprising:
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a first continuous electrical conductor;
a plurality of layers, N, each of said layers being defined by one substantially complete circumferential pass of said conductor around said stator core;
said conductor including a plurality of straight portions that lay within said predetermined radially projecting winding slots, and a plurality of end loop portions that extend circumferentially to connect two of said straight portions, wherein the length of said end loop portions varies based upon the radial location of said particular layer within said stator core and the end loop axial height varies between radial positions within said stator core based upon the radial location of a particular layer within said stator core. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
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16. A stator core assembly for an automotive alternator of the type having a rotor assembly and a stator assembly, said stator assembly of the type having at least one phase and having an annular core defining an outside diameter, an inside diameter, and a plurality of radially projecting winding slots opening to said inside diameter but terminating short of said outside diameter, said stator core assembly comprising:
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a continuous electrical conductor;
a plurality of layers, N, each of said layers being defined by one substantially circumferential pass of said conductor around said stator core;
said conductor includes a plurality of straight portions that lay within said predetermined radially projecting winding slots, and a plurality of end loop portions that extend circumferentially to connect two of said straight portions, wherein the length of said straight portions varies between radial positions within said stator core based upon the radial location of a particular layer within said stator core and the end lop axial height varies between radial positions within said stator core based upon the radial location of a particular layer within said stator core.
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17. A stator core assembly for an automotive alternator of the type having a rotor assembly and a stator assembly, said stator assembly of the type having at least one phase and having an annular core defining an outside diameter, an inside diameter, and a plurality of radially projecting winding slots opening to said inside diameter but terminating short of said outside diameter, said stator core assembly comprising:
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a continuous electrical conductor;
a plurality of layers, N, each of said layers being defined by one substantially circumferential pass of said conductor around said stator core;
said conductor includes a plurality of straight portions that lay within said predetermined radially projecting winding slots, and a plurality of end loop portions that extend circumferentially to connect two of said straight portions, wherein the shape of said end loop portions varies such that the end loop axial height varies between layers within said stator core based upon the radial location of a particular layer within said stator core.
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18. A stator core assembly for an automotive alternator of the type having a rotor assembly and a stator assembly, said stator assembly of the type having at least one phase and having an annular core defining an outside diameter, an inside diameter, and a plurality of radially projecting winding slots opening to said inside diameter but terminating short of said outside diameter, said stator core assembly comprising:
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a electrical conductor;
a plurality of layers, N, each of said layers being defined by one substantially circumferential pass of said conductor around said stator core;
said conductor includes a plurality of straight portions that lay within said predetermined radially projecting winding slots, and a plurality of end loop portions that extend circumferentially to connect two of said straight portions, and wherein the length of said straight portions is different in one layer than in another layer such that the axial height of said end loop portions of said one layer is different than the end loop axial height in said another layer. - View Dependent Claims (19, 20, 21, 22, 23, 24, 25)
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26. A stator core assembly for an automobile alternator of the type having a rotor assembly and a stator assembly, said stator assembly of the type having at least one phase and having an annular core defining an outside diameter, an inside diameter, and a plurality of radially projecting winding slots opening to said inside diameter but terminating short of said outside diameter, said stator core assembly comprising:
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a first electrical conductor;
at least a second electrical conductor;
a plurality of layers, N, each of said layers being defined by one substantially complete circumferential pass of said conductors around said stator core;
said conductors including a plurality of straight portions that lay within said predetermined radially projecting winding slots, and a plurality of end loop portions that extend circumferentially to connect two of said straight portions;
wherein the axial height of said end loop portions is constant for all layers, and said layers are axially shifted relative to each other in said stator core;
wherein said first conductor and said second conductor are cascaded within said winding slots circumferentially around said stator core. - View Dependent Claims (27)
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Specification