Method for electrically contacting at least one enameled copper wire with a component of an electric motor, generator, sensor or electromagnet by means of electrical contacts formed on the enameled copper wires and additional potting

Patent metadata

Field	Value
Publication number	US-12348097-B2
Application number	US-202217725239-A
Country	US
Kind code	B2
Filing date	Apr 20, 2022
Priority date	Apr 21, 2021
Publication date	Jul 1, 2025
Grant date	Jul 1, 2025

Abstract

A method of electrically contacting at least one enameled copper wire, which forms a winding carried by a first component, with a second component of an electric motor, generator, sensor or electromagnet. The method includes forming at least one wire end of the at least one enameled copper wire into an electrical contact, positioning the electrical contact in a molding process, a molding compound formed in the molding process at least partially surrounds the first component and the at least one wire end, and contacting the electrical contact with the second component.

First claim

What is claimed is:

1. A method of electrically contacting at least one enameled copper wire forming a winding carried by a first component with a second component of an electric motor, generator, sensor or electromagnet, the method comprising:
a) strengthening of at least one wire end of the at least one enameled copper wire by mechanical processing and/or surface treatment;
b) forming the at least one wire end into an electrical contact;
c) positioning the electrical contact in a forming process, wherein a forming compound formed in the forming process at least partially surrounds the first component and the at least one wire end; and
d) contacting the electrical contact with the second component; wherein
the electrical contact is a single projection which extends longitudinally in a straight line to define a plug-in contact which is inserted into the second component.

2. The method according to claim 1 , wherein
the method makes electrical contact between an armature winding of an armature and a commutator of a brushed electric motor;
the armature winding is defined by the at least one enameled copper wire, the wire end of which is formed into an electrical contact in b);
in c) the armature with the wire end is at least partially surrounded by the forming compound; and
in d) the electrical contact is made with the commutator.

3. The method according to claim 1 , wherein
the method makes electrical contact between a stator of an electric motor and a printed circuit board;
the stator includes a stator core and coils of the at least one enameled copper wire wound on the stator core;
in b) the at least one wire end belonging to a common phase is formed into an electrical contact;
in c) the electrical contact is connected to the stator, the forming compound formed in the forming process at least partially surrounding the at least one wire end and the stator; and
in d) the electrical contact is contacted to the printed circuit board.

4. The method according to claim 3 , wherein
in c) at least two longitudinally extending guide pins are formed on an upper side of the stator; and
in d) the guide pins are used to center the printed circuit board on the upper side of the stator.

5. The method according to claim 1 , wherein
the strengthening of the at least one wire end by mechanical processing and/or surface treatment includes a cold forming process.

6. The method according to claim 1 , wherein
in d) the electrical contact is directly press-fit into a portion of the printed circuit board.

7. An electric motor, comprising:
a first component carrying windings of enameled copper wire including wire ends;
a second component electrically contacted with the wire ends of the windings; and
at least one wire end is defined as an electrical contact contacting the second component; wherein
the electrical contact is held in position on the first component by a forming compound which is molded over at least a portion of the electrical contact with another portion of the electrical contact protruding out from a surface of the forming compound; and
the forming compound is made of plastic;
the electrical contact is a single projection which extends longitudinally in a straight line to define a plug-in contact which is inserted into the second component; and
the at least one wire end is strengthened by a portion that is mechanically hardened and/or surface treated.

8. The electric motor according to claim 7 , further comprising:
a commutator including a through bore extending in the longitudinal direction via which the commutator is non-rotatably mounted on an armature shaft of the electric motor; and
an armature body supported by the armature shaft; wherein
the windings of the enameled copper wire are on the armature body;
the electrical contact electrically contacts the windings with the commutator; and
the electrical contact is held in position on the armature body including the windings.

9. The electric motor according to claim 7 , further comprising:
a rotor which is mounted rotatably about an axis of rotation;
a stator including a stator core and coils wound on the stator core defining the windings; and
a printed circuit board, at least one wire end of each phase defined in the electrical contact contacting and the printed circuit board being the second component, the electrical contact being held in position on the stator, which is the first component.

10. The electric motor according to claim 9 , wherein the electrical contacts of all phases protrude from a forming compound.

11. The electric motor according to claim 9 , wherein the forming compound is molded over and surrounds the stator surface except for the electrical contacts of all phases.

12. The electric motor according to claim 9 , wherein at least two longitudinally extending guide pins are defined in the forming compound on an upper side of the stator.

13. The electric motor according to claim 7 , wherein two of the at least one wire ends are twisted together about a longitudinal axis and define the electrical contact extending in the longitudinal direction.

14. The electric motor according to claim 7 , wherein a wire end is twisted about a longitudinal axis and defines the electrical contact extending in a longitudinal direction.

15. The electric motor according to claim 7 , wherein the plastic of the forming compound is epoxy resin.

Assignees

• Nidec Gpm Gmbh
• Nidec Motors & Actuators Germany Gmbh

Inventors

• Nickel Conrad
• Schnitzer Jakob

Classifications

• H02K3/30

  Windings characterised by the insulating material · CPC title

• H02K5/225 Primary

  Terminal boxes or connection arrangements (specially adapted for submersible motors H02K5/132) · CPC title

• H02K11/33

  Drive circuits, e.g. power electronics (H02K11/38 takes precedence) · CPC title

• H02K3/522

  for generally annular cores with salient poles · CPC title

• H01R43/00

  Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors (of trolley lines B60M1/28) · CPC title