Electrical machine for a vehicle

Patent metadata

Field	Value
Publication number	US-11735986-B2
Application number	US-201916689047-A
Country	US
Kind code	B2
Filing date	Nov 19, 2019
Priority date	Nov 19, 2018
Publication date	Aug 22, 2023
Grant date	Aug 22, 2023

Abstract

A method for producing a stator for an electrical machine includes providing the stator including a ring-shaped stator body, from which a plurality of stator teeth arranged spaced apart along a circumferential direction of the stator body protrude radially to the inside. A space is thereby provided between two stator teeth adjacent to one another in the circumferential direction. Second, a first injection molding of two stator teeth adjacent to one another in the circumferential direction with a plastic is performed. Third, a stator winding is arranged in the space. Fourth, a second injection molding of the stator winding arranged in the space with the plastic is performed such that an air gap and/or an air trap between the stator teeth injection molded in the second step and the stator winding after the arrangement of the stator winding in the space in the third step, is filled with the plastic.

First claim

What is claimed is:

1. A method for producing a stator for an electrical machine, the method comprising the steps of:
(a) providing the stator including a plurality of stator teeth arranged spaced apart from one another along a circumferential direction of a stator body and a ring-shaped stator body, from which the plurality of stator teeth for accommodating stator windings protrude, wherein a space is in each case embodied between two stator teeth adjacent to one another in the circumferential direction;
(b) first injection molding of at least two stator teeth adjacent to one another in the circumferential direction with a plastic;
(c) arranging at least one stator winding in the space; and
(d) second injection molding of the at least one stator winding arranged in the space with the plastic, such that an air gap and/or air trap formed between the stator teeth injection molded in step (b) and the at least one stator winding after arranging the at least one stator winding in the space according to step (c), is filled with the plastic,
wherein at least one phase insulation, which is arranged in the space and which divides the space into a radially inner and into a radially outer subspace, is embodied during the injection molding with the plastic, such that first conductor elements of the at least one stator winding, which embody a first phase winding, can be arranged in a radially inner subspace, and second conductor elements of the at least one stator winding, which embody a second phase winding, which is electrically insulated with respect to the first phase winding, can be arranged in the radially outer subspace.

2. The method according to claim 1 , wherein an electrically insulating plastic is used at least in response to the first injection molding and/or additionally in response to the second injection molding.

3. The method according to claim 1 , wherein at least one masking, which is introduced into the space between the two stator teeth, is at least partially injection molded with the plastic, such that a volume of the space, which is filled by the at least one masking in response to the injection molding, remains free so as to embody a cooling duct.

4. The method according to one of claim 3 , further comprising:
injection molding the at least one masking during the second injection molding; or
injection molding the at least one masking in a separate method step.

5. The method according to claim 3 , wherein:
the at least one masking is arranged in a radially inner end section and/or in a radially outer end section of the space, and
a cooling duct is arranged in the radially inner end section or in the radially outer end section in response to the injection molding.

6. The method according to claim 1 , wherein the phase insulation is formed in response to the injection molding of the stator teeth or in response to the injection molding of the at least one stator winding or in a separate method step.

7. The method according to claim 1 , wherein the phase insulation extends along the circumferential direction and connects an insulation layer of the plastic arranged on adjacent stator teeth to one another.

8. The electrical machine according to claim 1 , wherein:
the plastic injected onto surface sections of the stator teeth is made of an electrically insulating first plastic material,
the plastic embodying at least one phase insulation is made of a second plastic material, and
the plastic embodying a first protective coating and/or a second protective coating is made of the second plastic material or of a third plastic material.

9. The electrical machine according to claim 8 , wherein:
the second plastic material is electrically insulating; and/or
the third plastic material is electrically conductive.

10. The electrical machine according to claim 8 , wherein:
at least one of the first plastic material, the second plastic material, or the third plastic material is a thermoplastic, and
at least one of the first plastic material, the second plastic material, or the third plastic material is a thermoset.

11. The electrical machine according to claim 8 , wherein at least one of the first, second, or third plastic materials have identical heat conductivities.

12. The electrical machine according claim 8 , wherein
at least two of the first, second, or third plastic materials are made of different materials.

13. The electrical machine according to claim 8 , wherein:
the second plastic material is electrically insulating; and/or
the third plastic material is electrically insulating.

14. The electrical machine according to claim 8 , wherein:
at least one of the first, second, or third plastic materials have different heat conductivities.

15. The electrical machine according claim 8 , wherein at least two of the first, second, or third plastic materials are made of different materials.

16. The method according to claim 1 , further comprising:
injection molding or filling, respectively, the space with the plastic such that the air gap is no longer present in the space after the injection molding or the filling, respectively.

17. The method according to claim 1 , wherein the space is embodied in a gap-free manner by the plastic.

18. The electrical machine comprising:
the stator produced by the method according to claim 17 ; and
a rotor configured to be rotatable about an axis of rotation relative to the stator.

19. The stator produced by the method according to claim 1 .

20. A method for producing a stator for an electrical machine, the method comprising the steps of:
(a) providing the stator including a plurality of stator teeth arranged spaced apart from one another along a circumferential direction of a stator body and a ring-shaped stator body, from which the plurality of stator teeth for accommodating stator windings protrude, wherein a space is in each case embodied between two stator teeth adjacent to one another in the circumferential direction;
(b) first injection molding of at least two stator teeth adjacent to one another in the circumferential direction with a plastic;
(c) arranging at least one stator winding in the space; and
(d) second injection molding of the at least one stator winding arranged in the space with the plastic, such that an air gap and/or air trap formed between the stator teeth injection molded in step (b) and the at least one stator winding after arranging the at least one stator winding in the space according to step (c), is filled with the plastic,
wherein:
the plastic injected onto surface sections of the stator teeth is made of an electrically insulating first plastic material,
the plastic embodying at least one phase insulation is made of a second plastic material, and
the plastic embodying a first protective coating and/or a second protective coating is made of the second plastic material or of a third plastic material.

Assignees

• Mahle Int Gmbh

Inventors

• Almeida E Silva Roberto
• Blankenbach Bernd
• Cox Terry
• Grabherr Philip
• Kull Niklas
• Male Tim
• Pisek Peter
• Sever Peter
• Sonntag Josef
• Williams Martin

Classifications

• H02K15/105 Primary

  to the windings · CPC title

• B29C45/14

  incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles {(B29C45/1671 takes precedence)} · CPC title

• H02K1/16

  Stator cores with slots for windings · CPC title

• H02K3/28

  Layout of windings or of connections between windings (windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32) · CPC title

• H02K9/197

  in which the rotor or stator space is fluid-tight, e.g. to provide for different cooling media for rotor and stator · CPC title