Coil for an electric machine and method for producing a coil

• US 9,035,523 B2
• Filed: 05/05/2009
• Issued: 05/19/2015
• Est. Priority Date: 05/05/2008
• Status: Active Grant

• Current Assignee: Marcus Podack
• Original Assignee: Brose Fahrzeugteile GmbH & Company KG Wã¼Rzburg
• Inventors: Podack, Marcus
• Primary Examiner(s): GONZALEZ QUINONES, JOSE A
• Application Number:
  US12/991,034
• Publication Number:
  US 20110127872A1
• Time in Patent Office: 2,205 Days
• Field of Search: 310/180, 310/208, 310/201, 310/202, 310/203, 310/216.073, 310/216.074, 310/216.079, 310/216.85, 310/216.99, 310/216.101, 310/216.102, 295/96
• 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 for an electric machine for conducting an electric current for generating a magnetic field, the coil comprising:

individual turns which are embodied from a conductive sheet-metal strip material, and the turns are embodied generally as flat bodies of rectangular shape comprising two narrow sides and two long sides, in such a manner that a dense package with turns arranged one on top of the other is obtained, and each turn has at least one circumferential conductor track with the exception of at least one electrical interruption on one of the long sides resulting in a first end and a second end of the turn, and the conductor track of a turn at one location has an electrically conductive connection to a conductor track of an adjacent turn, wherein the turns are, apart from this, substantially electrically insulated from one another, and wherein a contact region for a current connection is provided at at least one end-side turn of the coil, wherein the contact region extends from one of the narrow sides of the end-side turn and provides a third end of the end-side turn and wherein the coil is adapted to be fittable onto a tooth of a star in the sense of an individual tooth coil, wherein a periphery of each tooth has a substantially constant outer diameter and wherein all the turns of the individual tooth coil are made narrower in the vicinity of a foot region of a tooth than in a shoulder region of a tooth and are sized to form an exposed groove with an adjacent coil, wherein an entirety of the exposed groove has a width which increases from the shoulder region to the foot region.

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

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

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

5. The coil as claimed in claim 1, wherein the turns are embodied as flat bodies of rectangular shape and wherein a dimension of each turn increases from the foot region to the shoulder region.

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

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

8. The coil as claimed in claim 1, wherein the electrically conductive connection between the turns 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 is constructed and arranged to be assembled outside the electric machine, including the electrically conductive connections between the turns, 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 in such a way that the interruptions and/or the electrically conductive connections are arranged in a groove region of the stator.

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

12. The coil as claimed in claim 1, wherein the contact region 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 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 claim 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.

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

at least one coil having individual turns which are embodied from a conductive sheet-metal strip material, and the turns are embodied generally as flat bodies of rectangular shape comprising two narrow sides and two long sides, in such a manner that a dense package with turns arranged one on top of the other is obtained, and each turn has at least one circumferential conductor track with the exception of at least one electrical interruption on one of the long sides, and the conductor track of a turn at one location has an electrically conductive connection to a conductor track of an adjacent turn, wherein the turns are, apart from this, substantially electrically insulated from one another, wherein a contact region for a current connection is provided at at least one end-side turn of the coil, wherein the contact region extends from one of the narrow sides of the end-side turn and provides a third end of the end-side turn, and

a star yoke structure,

wherein the coil is fitted onto a tooth of a star in the sense of an individual tooth coil, wherein a periphery of each tooth has a substantially constant outer diameter and wherein all the turns of the individual tooth coil are made narrower in the vicinity of a foot region of a tooth than in a shoulder region of a tooth and are sized to form an exposed groove with an adjacent coil, wherein an entirety of the exposed groove has a width which increases from the shoulder region to the foot region.

17. 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.

18. A method for producing a coil, the method comprising:

providing rectangular flat turns which are embodied from a conductive sheet-metal strip material and wherein each rectangular flat turn comprises two narrow sides and two long sides, and which have a gap-shaped interruption in one of the long sides,

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

assembling the coil outside the electric machine, including the electrically conductive connections between the turns, and

subsequently inserting the coil into the electric machine,

wherein a contact region for a current connection is provided at at least one end-side turn of the coil, wherein the contact region extends from one of the narrow sides of the end-side turn and provides a third end of the end-side turn and wherein the coil is adapted to be fittable onto a tooth of a star in the sense of an individual tooth coil, wherein a periphery of each tooth has a substantially constant outer diameter and wherein all the turns of the individual tooth coil are made narrower in the vicinity of a foot region of a tooth than in a shoulder region of a tooth and are sized to form an exposed groove with an adjacent coil, wherein an entirety of the exposed groove has a width which increases from the shoulder region to the foot region.

19. The method as claimed in claim 18, wherein the electrically conductive connections between the turns 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.

20. The method as claimed in claim 18, wherein a bonding agent which can be activated thermally is used for mechanically securing the turns to one another before the turns are insulated from one another.

21. A method for producing a stator, the method comprising:

providing at least one coil having individual turns which are embodied from a conductive sheet-metal strip material, and the turns are embodied generally as flat bodies of rectangular shape, wherein each rectangular flat turn comprises two narrow sides and two long sides, in such a manner that a dense package with turns arranged one on top of the other is obtained, and each turn has at least one circumferential conductor track with the exception of at least one electrical interruption on one of the long sides, and the conductor track of a turn at one location has an electrically conductive connection to a conductor track of an adjacent turn, wherein the turns are, apart from this, substantially electrically insulated from one another, and wherein a contact region for a current connection is provided at at least one end-side turn of the coil, wherein the contact region extends from of the narrow sides of the of the end-side turn and provides a third end of the end-side turn, and

providing a star yoke structure,

wherein the coil is formed by stacking up individual flat turns outside the stator and is soldered together in order to produce individual, electrically conductive connections in a groove region of the stator, and the coil is subsequently fitted as a coil package onto one tooth of a star of a star yoke structure in the sense of an individual tooth coil, wherein a periphery of each tooth has a substantially constant outer diameter, and subsequently after the fitting onto the star, the star is inserted into a yoke, wherein all the turns of the individual tooth coil are made narrower in the vicinity of a foot region of a tooth than in a shoulder region of a tooth and are sized to form an exposed groove with an adjacent coil, wherein an entirety of the exposed groove has a width which increases from the shoulder region to the foot region.