Coil for a compressor which can be electrically driven, and corresponding production method

Patent metadata

Field	Value
Publication number	US-2016164362-A1
Application number	US-201414906917-A
Country	US
Kind code	A1
Filing date	Jul 29, 2014
Priority date	Aug 2, 2013
Publication date	Jun 9, 2016
Grant date	—

Abstract

A method for producing a coil of a compressor ( 1 ) which can be electrically driven, a coil which is produced in accordance with this method, and a stator and a compressor which can be electrically driven. The production process for the coil includes the steps of: producing ( 100 ) a first winding ( 101 ) of the coil ( 12 ), producing ( 200 ) a second winding ( 102 ) of the coil ( 12 ), and compacting ( 300 ) the first winding ( 101 ) and the second winding ( 102 ) by virtue of an external action of force. A cross-sectional area ( 111, 112, 111′, 112′ ) of a wire of the first winding ( 101 ) and of the second winding ( 102 ) is deformed.

First claim

1 . A method for producing a coil ( 12 ) of a compressor ( 1 ) which can be electrically driven, comprising the steps of:
producing (S 100 ) a first winding ( 101 ) of the coil ( 12 ), producing (S 200 ) a second winding ( 102 ) of the coil ( 12 ), compacting (S 300 ) the first winding ( 101 ) and the second winding ( 102 ) by virtue of an external action of force, wherein a cross-sectional area of a wire ( 111 , 111 ′) of the first winding ( 101 ) and a wire ( 121 , 121 ′) of the second winding ( 102 ) is deformed.

2 . The method as claimed in claim 1 , wherein, in a first step, the first winding ( 101 ) is compacted together with a first multiplicity of windings, and, in a second step, the second winding ( 102 ) is compacted together with a second multiplicity of windings to form a coil ( 12 ).

3 . The method as claimed in claim 1 , wherein the windings ( 101 , 102 ) of the coil ( 12 ) are arranged between substantially parallel surfaces ( 106 , 107 ) of two tool parts ( 104 , 105 ) and are compacted by one, preferably two, dies ( 108 , 109 ) in a direction (P a , P b ) parallel to the surfaces ( 106 , 107 ) of the two tool parts ( 104 , 105 ).

4 . The method as claimed in claim 3 , wherein the surfaces ( 106 , 107 ) of the tool parts ( 104 , 105 ) have a curvature which serves to match the coil ( 12 ) to an air gap between a stator and a rotor of an electrical machine ( 7 ) for the purpose of driving the compressor ( 1 ).

5 . The method as claimed in claim 1 , wherein the coil is compacted in a magnetically active section, in particular a winding head ( 25 a , 25 b ) of the coil is also compacted, after all of the windings ( 101 , 102 ) of the coil are produced.

6 . A coil for an electrically driven compressor ( 1 ) obtained by the method as claimed in claim 1 .

7 . A stator for an electrical drive of a compressor ( 1 ), comprising a coil as claimed in claim 6 .

8 . The stator as claimed in claim 7 , comprising three coils which are arranged in a delta circuit by adjacent electrical connections of two coils being combined in each case for the purpose of allowing an external electrical connection to make contact with said electrical connections.

9 . The stator as claimed in claim 7 , the coils of said stator being fixed relative to one another by means of a cured fluid.

10 . A compressor ( 1 ) for an internal combustion engine, which compressor can be electrically driven and comprises an electrical drive having a stator as claimed in claim 7 .

11 . The method as claimed in claim 1 , wherein each wire comprises a plurality of copper strands encased in insulation.

12 . The method as claimed in claim 1 , wherein the second winding is compacted subsequent to the first winding.

13 . The method as claimed in claim 1 , wherein the first and second windings are compacted together.

14 . A method for producing a coil ( 12 ) of a compressor ( 1 ) which can be electrically driven, comprising the steps of:
(a) producing (S 100 ) a first winding ( 101 ) as one loop of a conductor, (b) compacting the first winding by virtue of an external action of force, wherein a cross-sectional area of a wire ( 111 , 111 ′) of the first winding ( 101 ) is deformed, (c) producing (S 200 ) a second winding ( 102 ) as one loop of a conductor, (d) compacting the second winding by virtue of an external action of force, wherein a cross-sectional area of a wire ( 121 , 121 ′) of the second winding ( 102 ) is deformed, (e) arranging the products of steps (c) and (d) on a tool to form a compacted coil.

15 . A method for producing a coil ( 12 ) of a compressor ( 1 ) which can be electrically driven, comprising the steps of:
(a) producing (S 100 ) a first winding ( 101 ) as one loop of a conductor and producing (S 200 ) at least a second winding ( 102 ) as a second loop of the conductor, (b) compacting the first winding and the second winding together by virtue of an external action of force, wherein a cross-sectional area of a wire ( 111 , 111 ′) of the first winding ( 101 ) and a cross-sectional area of a wire ( 121 , 121 ′) of the second winding ( 102 ) is deformed.

16 . The method as claimed in claim 1 , wherein, in a first step, a first multiplicity of windings is compacted together, and, in a second step, a second multiplicity of windings is compacted together to form a coil.

17 . The method as claimed in claim 2 , wherein volume of the coil ( 12 ) is reduced by 5% to 30%.

18 . The method as claimed in claim 2 , wherein volume of the coil ( 12 ) is reduced by 10% to 20%.

19 . The stator as claimed in claim 7 , the coils of said stator being fixed relative to one another by means of a cured insulating enamel or adhesive.

Assignees

• Borgwarner Inc

Inventors

• Lehner Hans
• Metz Dietmar

Classifications

• F04D29/5813

  Cooling the control unit · CPC title

• H02K3/38

  around winding heads, equalising connectors, or connections thereto · CPC title

• F04D25/0606

  the electric motor being specially adapted for integration in the pump · CPC title

• H01F41/06

  Coil winding · CPC title

• F02B39/10

  electric · CPC title