Coil wire for coil assembly for rotary electrical machine

• US 8,018,112 B2
• Filed: 06/30/2009
• Issued: 09/13/2011
• Est. Priority Date: 06/30/2008
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Dobashi, Masaomi, Akimoto, Akito
• Primary Examiner(s): Leung; Quyen
• Assistant Examiner(s): Mok; Alex W
• Application Number:
  US12/494,656
• Publication Number:
  US 20090322178A1
• Time in Patent Office: 805 Days
• Field of Search: 310/195, 310/179, 310/180
• US Class Current: 310/180
• CPC Class Codes: H02K 15/0037 Shaping or compacting winding heads H02K15/005, H02K15/0087 and H02K15/0428 take precedence
• CPC Class Codes: H02K 15/0478 Wave windings, undulated windings when on diagonally wound hollow coils H02K15/0492
• CPC Class Codes: H02K 3/12 arranged in slots

Abstract

A coil wire for a coil assembly of a rotating electrical machine is provided such that sufficient space in braiding is secured when coil-wire-bundles bundling a plurality of the coil wires are braided. Each of the coil wires has a predetermined length, a plurality of straight portions and a plurality of turn portions, the straight portions linearly-extend in parallel in a first direction substantially perpendicular to the overall length direction of the coil wires, the turn portions connect two of the straight portions to be adjacent via first-kinked-portions and second-kinked-portions, the first-kinked-portions are kinked in a second direction substantially perpendicular to both the first direction and the length direction of the coil wires, the second-kinked-portions are kinked in a third direction substantially opposite to the second direction so that the turn portions are formed in a wave-shape in the length direction of the coil wires.

Claims

1. A plurality of coil wires braided to each other for forming a coil assembly for a rotating electric machine in which:

each of the coil wires has a predetermined length, a plurality of straight portions and a plurality of turn portions;

said straight portions linearly extending in parallel to each other in a first direction substantially perpendicular to a length direction of said coil wires and substantially parallel to an axis of the coil assembly, each of said turn portions connecting adjacent two of said straight portions along the length of the respective coil wire alternately via a first-kinked-portion and a second-kinked-portion, respectively, said first-kinked-portions being kinked in a second direction substantially perpendicular to both the first direction and the length direction of said coil wires, said second-kinked-portions being kinked in a third direction substantially opposite to the second direction so that said turn portions are formed in a wave-shape in the length direction of said coil wires, wherein

each of the turn portions has first steps leading to the adjacent two straight portions and a center portion located between the first steps, the first steps and the center portion each extending substantially perpendicular to the straight portions, the center portion being located farther from the straight portions than the first steps in the first direction, the center portion having a crank portion bent in a plane of the center portion that is substantially perpendicular to the first direction.

2. A plurality of coil wires as set forth in claim 1, wherein said first and said second kinked-portions are kinked relative to an axis line of each of the coil wires at said straight portions.

3. A plurality of coil wires as set forth in claim 1, wherein each of said turn portions further has a second step between each first step and the center portion, with the first and second steps extending between the center portion and each adjacent straight portion in a staircase pattern.

4. A stator core for a rotating electrical machine comprising:

a stator core being formed in substantially circular form and having a plurality of slots in a circumferential direction of the stator core;

a coil assembly being formed by braiding a plurality of coil wires;

each of said coil wires has a predetermined length, and including a plurality of in-slot-portions and a plurality of turn portions, said in-slot-portions being disposed in said stator core slots, and said in-slot-portions linearly extending in parallel in a first direction substantially perpendicular to the length direction of said coil wires and substantially parallel to an axis of the coil assembly, each of said turn portions being arranged outside of either-or both ends of said stator core, and said turn portions connecting adjacent two of said in-slot-portions along the length of the respective coil wire alternately via a first-kinked-portion and a second-kinked-portion, respectively, said first-kinked-portions being kinked in a second direction substantially perpendicular to both the first direction and the length direction, said second-kinked-portions being kinked in a third direction substantially opposite to the second direction so that said turn portions are formed in a wave-shape in the length direction of said coil wires, wherein

each of the turn portions has first steps leading to the adjacent two straight portions and a center portion located between the first steps, the first steps and the center portion each extending substantially perpendicular to the straight portions, the center portion being located farther from the straight portions than the first steps in the first direction, the center portion having a crank portion bent in a plane of the center portion that is substantially perpendicular to the first direction.

5. A stator core as set forth in claim 4, wherein said first and second kinked-portions are kinked relative to an axis line of each of the coil wires at said straight portions.

6. A stator core as set forth in claim 4, wherein said turn portions are braided so that said turn portions of the coil wires to be adjacent are mutually offset in the length directions of said coil wires and cross each other.

7. A plurality of coil wires as set forth in claim 4, wherein each of said turn portions further has a second step between each first step and the center portion, with the first and second steps extending between the center portion and each adjacent straight portion in a staircase pattern.