Coil assembly, armature and rotating electric machine

Patent metadata

Field	Value
Publication number	US-2024266895-A1
Application number	US-202418638252-A
Country	US
Kind code	A1
Filing date	Apr 17, 2024
Priority date	Oct 18, 2021
Publication date	Aug 8, 2024
Grant date	—

Abstract

A coil assembly includes a band member and a plurality of coils. The band member is rolled along a circumferential direction into an annular shape and has a plurality of layers in a radial direction. The coils have vertical portions, and are located at predetermined positions in the circumferential direction and the radial direction on the band member and connected in a predetermined connection pattern. Moreover, the coil assembly further includes vertical-portion laminates constituted of the vertical portions of the coils which are radially laminated in a cross section of the band member and the coils taken along the radial direction. Each of the vertical-portion laminates is configured so that each radially-adjacent pair of the vertical portions constituting the vertical-portion laminate have different electric potentials when the coils are energized.

First claim

What is claimed is:

1 . A coil assembly comprising:
a band member formed of an electrically-insulative material into a band shape and rolled along a circumferential direction into an annular shape, the band member having a plurality of layers in a radial direction; a plurality of coils formed of an electroconductive material on the band member and having vertical portions, the coils being located at predetermined positions in the circumferential direction and the radial direction on the band member and connected in a predetermined connection pattern; and a plurality of vertical-portion laminates constituted of the vertical portions of the coils which are radially laminated in a cross section of the band member and the coils taken along the radial direction, each of the vertical-portion laminates being configured so that each radially-adjacent pair of the vertical portions constituting the vertical-portion laminate have different electric potentials when the coils are energized, wherein: the plurality of coils include a plurality of coils of a designated phase; the coils of the designated phase are arranged in alignment with one another in the circumferential direction; the plurality of vertical-portion laminates include a plurality of vertical-portion laminates of the designated phase; each of the vertical-portion laminates of the designated phase is constituted of the vertical portions of the coils of the designated phase which are formed respectively on the plurality of layers of the band member and radially laminated together; a first configuration or a second configuration is employed for the coils of the designated phase; in the first configuration, every predetermined number of the coils of the designated phase are connected in series with each other, and the electric potential difference between each radially-adjacent pair of the vertical portions in each of the vertical-portion laminates of the designated phase is greater than or equal to 1.5×V/s, where V is the electric potential difference between two ends of each serial connection of the coils of the designated phase, and s is the number of the coils of the designated phase included in each serial connection; and in the second configuration, none of the coils of the designated phase are connected in series with the other coils of the designated phase, and the electric potential difference between each radially-adjacent pair of the vertical portions in each of the vertical-portion laminates of the designated phase is greater than or equal to V/2.

2 . The coil assembly as set forth in claim 1 , wherein:
the vertical-portion laminates of the designated phase constitute a conductor group of the designated phase; and a circumferential dimension of the conductor group is set to be greater than a radial dimension of each of the vertical-portion laminates constituting the conductor group.

3 . The coil assembly as set forth in claim 1 , wherein:
for each of the plurality of vertical-portion laminates, a radial dimension of the vertical-portion laminate is set to be greater than a circumferential dimension of the vertical-portion laminate.

4 . The coil assembly as set forth in claim 1 , wherein:
for each of the vertical portions of the plurality of coils, a circumferential dimension of the vertical portion is set to be greater than a radial dimension of the vertical portion.

5 . The coil assembly as set forth in claim 1 , wherein:
all the coils of the designated phase are physically wound in one direction; and the coils of the designated phase are connected so that when they are energized, they function identically to coils of the designated phase wound in a first direction and coils of the designated phase wound in a second direction which are arranged alternately in the circumferential direction, the second direction being opposite to the first direction.

6 . The coil assembly as set forth in claim 1 , wherein:
in a state of the band member having been rolled along the circumferential direction a plurality of times, a plurality of connection portions of the designated phase, which are connected with the coils of the designated phase, extend from an annularly-rolled part of the band member to one side in an axial direction; and the connection portions of the designated phase are arranged in radial alignment with each other and bundled together.

7 . The coil assembly as set forth in claim 1 , wherein:
in a state of the band member having been rolled along the circumferential direction a plurality of times, a plurality of connection portions of the designated phase, which are connected with the coils of the designated phase, extend from an annularly-rolled part of the band member to one side in an axial direction; the connection portions of the designated phase are arranged in radial alignment with each other and bent to one side in the radial direction; and lengths of the connection portions of the designated phase gradually decrease toward the one side in the radial direction.

8 . The coil assembly as set forth in claim 1 , wherein:
circumferential dimensions of the vertical portions constituting the plurality of vertical-portion laminates gradually increase toward an outer side in the radial direction.

9 . The coil assembly as set forth in claim 1 , wherein:
at least a portion of each of the plurality of coils is divided by a slit.

10 . The coil assembly as set forth in claim 1 , wherein:
a portion of one of the coils of the designated phase and a portion of another one of the coils of the designated phase constitute a pair of equipotential portions; and the pair of equipotential portions are connected with each other via a voltage-equalizing connection portion.

11 . The coil assembly as set forth in claim 1 , wherein:
a sensor is mounted to the band member.

12 . An armature comprising the coil assembly as set forth in claim 1 .

13 . A rotating electric machine comprising:
a stator; and a rotor, wherein: one of the stator and the rotor includes the armature as set forth in claim 12 , and the other of the stator and the rotor has magnets arranged to radially face the coil assembly.

14 . The rotating electric machine as set forth in claim 13 , wherein:
the plurality of coils have first coil end portions on a first side of the vertical portions in the axial direction and second coil end portions on a second side of the vertical portions in the axial direction; and an axial dimension of the magnets is set to be greater than an axial dimension of the vertical portions and less than an axial dimension of the plurality of coils including the first coil end portions, the vertical portions and the second coil end portions.

15 . A coil assembly comprising:
a band member formed of an electrically-insulative material into a band shape and rolled along a circumferential direction into an annular shape, the band member having a plurality of layers in a radial direction; a plurality of coils formed of an electroconductive material on the band member and having vertical portions, the coils being located at predetermined positions in the circumferential direction and the radial direction on the band member and connected in a predetermined connection pattern; and a plurality of vertical-portion laminates constituted of the vertical portions of the coils which are radially laminated in a cross section of the band member and the coils taken along the radial direction, each of the vertical-portion laminates being configured so that each radially-adjacent pair of the vertical portions constituting the ve

Assignees

• Denso Corp

Inventors

• Hayashi Yuji
• Yamamoto Toshio

Classifications

• H02K3/28 Primary

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

• H02K3/04

  Windings characterised by the conductor shape, form or construction, e.g. with bar conductors · CPC title

• H02K21/14

  with magnets rotating within the armatures · CPC title

• H02K11/21 Primary

  Devices for sensing speed or position, or actuated thereby (specially adapted for machines having non-mechanical commutating devices H02K29/06, H02K29/14) · CPC title