Electric machine with electrical connector

Patent metadata

Field	Value
Publication number	US-10181658-B2
Application number	US-201615087880-A
Country	US
Kind code	B2
Filing date	Mar 31, 2016
Priority date	Mar 31, 2016
Publication date	Jan 15, 2019
Grant date	Jan 15, 2019

Abstract

An electric machine having a rotor, stator and at least one winding. The winding defines a first lead having a conductive core and an electrically insulative exterior layer. A connector engaged with the first lead includes a plurality of projections that pierce the exterior layer of the first lead to engage the conductive core. The connector may be C-shaped having a spine and first and second arms with first and second bend lines respectively disposed between the spine and the two arms. Alternatively, the connector may be U-shaped having a spine and first and first and second arms wherein a bend line and a central opening are disposed between the two arms. The first lead extends through the central opening and is grippingly engaged by the connector between the first and second arms. The connector may also be used to securely engage an uninsulated terminal.

First claim

What is claimed is:

1. An electric machine comprising:
a rotor and a stator wherein the stator includes at least one winding;
a first end of the winding defining a first lead, the first lead of the winding having an exterior layer of an electrically insulative material disposed on an electrically conductive core;
a conductive member; and
a connector conductively coupled with the conductive member for conductively connecting the conductive member with the first lead, the connector being formed of an electrically conductive material and being crimped to engage the first lead, the connector including a plurality of projections wherein the projections pierce the exterior layer of the first lead to engage the conductive core of the first lead and wherein the plurality of projections engage the first lead on opposing sides of the first lead whereby at least a portion of the projections engaged with the conductive core project toward each other.

2. The electric machine of claim 1 wherein the connector conductively connects the conductive member with a second lead wherein the second lead has an exterior layer of an electrically insulative material disposed on an electrically conductive core and the projections pierce the exterior layer of the second lead to engage the conductive core of the second lead and wherein the plurality of projections engage the second lead on opposing sides of the second lead whereby at least a portion of the projections engaged with the conductive core project toward each other.

3. The electric machine of claim 1 wherein the connector is a C-shaped connector having a spine and first and second arms disposed on opposite sides of the spine, the connector further defining first and second bend lines respectively disposed between the spine and the first and second arms, the first lead being an elongate element defining an axis wherein the axis of the first lead and the first and second bend lines of the connector are all arranged parallel with each other.

4. The electric machine of claim 3 wherein the plurality of projections define a plurality of parallel, linearly extending projections, the projections each extending in a direction perpendicular to the first and second bend lines.

5. The electric machine of claim 4 wherein each of the linearly extending projections extends across the first and second arms and the spine from a distal edge of the first arm to a distal edge of the second arm.

6. The electric machine of claim 1 wherein the conductive member includes a projecting terminal conductively coupled with the connector having an exterior surface defined by a conductive material and the terminal is disposed between one of the first and second arms and the spine and is conductively engaged by at least a portion of the plurality of projections.

7. The electric machine of claim 1 wherein the connector comprises a plurality of connectors, each connector being conductively connected to a pair of leads wherein each lead of the pair of leads forms the end of a stator winding.

8. The electric machine of claim 1 wherein the connector is a U-shaped connector having a spine and first and first and second arms disposed on opposite sides of the spine, the connector further defining at least one bend line between the first and second arms, the connector further defining a central opening disposed between the first and second arms; and
wherein the first lead extends through the central opening and is grippingly engaged by the connector between the first and second arms.

9. The electric machine of claim 8 wherein the first lead defines an axis that extends perpendicular to the at least one bend line and wherein the plurality of projections define a plurality of parallel, linearly extending projections, the plurality of projections each extending in a direction parallel to the at least one bend line, a first portion of the plurality of projections being disposed on the first arm and a second portion of the plurality of projections being disposed on the second arm.

10. The electric machine of claim 1 wherein the connector comprises a plurality of connectors, each connector being integrally formed with the conductive member and conductively connecting a pair of leads to the conductive member and wherein each lead of the pair of leads forms the end of a stator winding.

11. An electric machine comprising:
a rotor and a stator wherein the stator includes at least one winding;
a first end of the winding defining a first lead, the first lead of the winding having an exterior layer of an electrically insulative material disposed on an electrically conductive core;
a conductive member having a projecting terminal wherein the terminal has an exterior surface defined by a conductive material; and
a connector conductively coupled with the conductive member for conductively connecting the conductive member with the first lead, the connector being formed of an electrically conductive material and being crimped to engage the first lead and the terminal, the connector including a plurality of projections wherein the projections pierce the exterior layer of the first lead to engage the conductive core of the first lead and wherein the plurality of projections engage the terminal to thereby conductively couple the terminal with the first lead.

12. The electric machine of claim 11 wherein the plurality of projections engaged with the terminal pierce the exterior surface of the terminal and partially penetrate the terminal and wherein the terminal defines a first thickness more than twice a projecting length of the plurality of projections.

13. The electric machine of claim 12 wherein the lead defines a second thickness which is more than twice the projecting length of the plurality of projections.

14. The electric machine of claim 13 wherein each of the first and second thicknesses are at least four times the projecting length of the plurality of projections.

15. The electric machine of claim 11 wherein the connector is a C-shaped connector having a spine and first and second arms disposed on opposite sides of the spine, the connector further defining first and second bend lines respectively disposed between the spine and the first and second arms, the first lead and the terminal each being an elongate element defining an axis wherein the axes of the first lead and the terminal and the first and second bend lines of the connector are all arranged parallel with each other.

16. The electric machine of claim 11 wherein the connector is a U-shaped connector having a spine and first and first and second arms disposed on opposite sides of the spine, the connector further defining at least one bend line between the first and second arms, the connector further defining a central opening disposed between the first and second arms; and
wherein the first lead and the terminal both extend through the central opening and are grippingly engaged by the connector between the first and second arms.

17. An electric machine comprising:
a rotor and a stator wherein the stator includes at least one winding;
a first end of the winding defining a first lead, the first lead of the winding having an exterior layer of an electrically insulative material disposed on an electrically conductive core;
a conductive member and a connector wherein the conductive member and the connector are both formed from a single sheet of conductive metal material; and
wherein the connector conductively connects the conductive member with the first lead, the connector being crimped to engage the first lead, the connector inc

Assignees

• Remy Tech Llc
• Borgwarner Inc

Inventors

• Neet Kirk
• Bledsoe Christopher
• Murphy James Paul

Classifications

• H01R4/206

  with transversal grooves or threads · CPC title

• H02K11/0094

  Structural association with other electrical or electronic devices · CPC title

• H02K3/50

  Fastening of winding heads, equalising connectors, or connections thereto · CPC title

• H01R4/2495

  Insulation penetration combined with permanent deformation of the contact member, e.g. crimping · CPC title

• H02K11/049 Primary

  Rectifiers associated with stationary parts, e.g. stator cores · CPC title