Coil assembly, armature, and rotating electrical machine

Patent metadata

Field	Value
Publication number	US-2024388157-A1
Application number	US-202418785292-A
Country	US
Kind code	A1
Filing date	Jul 26, 2024
Priority date	Jan 28, 2022
Publication date	Nov 21, 2024
Grant date	—

Abstract

A coil assembly includes a plurality of strip members which are rolled or wound in a circumferential direction of the coil assembly. The strip members have at least portions overlapping each other in a radial direction of the coil assembly and stacked on one another in the radial direction of the coil assembly. The strip members have a plurality of coils disposed thereon. The coil assembly also has a thin-walled portion and thick-walled portions. The thin-walled portion is defined by a portion of the strip members and has a first thickness in the radial direction. The thick-walled portions are defined by portions of the strip members and have a second thickness in the radial direction which is greater than the first thickness. The thick-walled portions are arranged away from each other in the circumferential direction.

First claim

1 . A coil assembly comprising:
a plurality of strip members which are made from an electrically insulating material, rolled in a circumferential direction of the coil assembly, and stacked on one another in a radial direction of the coil assembly, the strip members having at least portions overlapping each other in the radial direction of the coil assembly; a plurality of coils which are made from an electrically conductive material and formed on the strip members, the coils being arranged in the circumferential direction; a thin-walled portion which is defined by a portion of the strip members and has a first thickness in the radial direction; and a plurality of thick-walled portions which are defined by portions of the strip members and have a second thickness in the radial direction which is greater than the first thickness, the thick-walled portions being arranged away from each other in the circumferential direction.

2 . The coil assembly as set forth in claim 1 , wherein the thick-walled portions are arranged away from each other both in a circumferential range of 0° to 180° and in a circumferential range of 180° to 360°,
a first one of the thick-walled portions has at least a portion located at an angular interval of 180° away from at least a portion of a second one of the thick-walled portions in the circumferential direction of the coil assembly, or
at least a portion of one of the thick-walled portions is located at an angular interval of 180° away from a region where at least two of the thick-walled portions are arranged successively adjacent to each other in the circumferential direction of the coil assembly.

3 . The coil assembly as set forth in claim 1 , wherein each of the strip members has a connector which extends therefrom and electrically connects with the coils, and
the connectors of the strip members are arranged to coincide with each other in the circumferential direction of the coil assembly.

4 . The coil assembly as set forth in claim 1 , wherein each of the strip members has a connector which extends therefrom and electrically connects with the coils, and
the connectors of the strip members are located away from each other in the circumferential direction of the coil assembly.

5 . The coil assembly as set forth in claim 3 , wherein the connectors extending from the strip members are located in one of the thick-walled portions.

6 . The coil assembly as set forth in claim 3 , wherein the connectors extending from the strip members are located in the thin-walled portion.

7 . A coil assembly comprising:
a strip member which is made from an electrically insulating material and rolled in a circumferential direction of the coil assembly to have turns stacked in a radial direction of the coil assembly, the strip members having at least portions overlapping each other in the radial direction of the coil assembly; coils which are made from an electrically conductive material and formed on the strip members, the coils being arranged in the circumferential direction; a thin-walled portion which is defined by a portion of the strip members and has a first thickness in the radial direction; and a plurality of thick-walled portions which are defined by portions of the strip members and have a second thickness in the radial direction which is greater than the first thickness, the thick-walled portions being arranged away from each other in the circumferential direction.

8 . An armature comprising:
an armature core which is made from a soft magnetic material in a form of a hollow cylinder; and a coil assembly set forth in claim 1 , the coil assembly being arranged on one of a radial inner peripheral surface or a radial outer peripheral surface of the armature core.

9 . The coil assembly as set forth in claim 8 , further comprising an adhesive material is disposed in a clearance defined between the armature core and the thin-walled portion to achieve adhesion between the armature core and the coil assembly.

10 . The coil assembly as set forth in claim 8 , further comprising a shoulder which is formed at a boundary between the thin-walled portion and one of the thick-walled portions and located close to the armature core, the shoulder having a height in the radial direction of the coil assembly.

11 . The coil assembly as set forth in claim 8 , further comprising an annular insulator which is made from an electrically insulating material and has a length with a first end and a second end which are laid to overlap each other in the radial direction of the coil assembly,
the insulator is disposed between the armature core and the coil assembly to have the first and second ends arranged in a clearance formed between the armature core and the thin-walled portion of the coil assembly.

12 . The coil assembly as set forth in claim 8 , wherein one of the strip members which is located closest to the armature core has a coil-unoccupied portion where no coils are formed,
the coil-unoccupied portion is curved and extends in a circumferential direction of the coil assembly to serve as an insulator located close to the armature coil, the insulator having portions which are laid to overlap each other in the radial direction of the coil assembly and arranged in a clearance formed between the armature core and the thin-walled portion of the coil assembly.

13 . An armature comprising:
an armature core which is made from a soft magnetic material in a form of a hollow cylinder; a coil assembly which is arranged on one of a radial inner peripheral surface and a radial outer peripheral surface of the armature core and includes a strip member, a plurality of coils, a thin-walled portion, and thick-walled portions, the strip member being made from an electrically insulating material and wound a plurality of times in a circumferential direction of the coil assembly, the coils being made from an electrically conductive material and arranged in a circumferential direction of the coil assembly, the thin-walled portion being defined by a portion of the strip member and having a first thickness in a radial direction of the coil assembly, the thick-walled portions being defined by portions of the strip member and having a second thickness in the radial direction which is greater than the first thickness, and an annular insulator which is made from an electrically insulating material and has a length with a first end and a second end which are laid to overlap each other in the radial direction of the coil assembly, the insulator being disposed between the armature core and the coil assembly to have the first and second ends arranged in a clearance formed between the armature core and the thin-walled portion of the coil assembly.

14 . A rotating electrical machine comprising:
a first one of a stator and a rotor which includes an armature set forth in claim 8 ; and a second one of the stator and the rotor which includes magnets arranged to face a coil assembly in a radial direction of the coil assembly.

Assignees

• Denso Corp

Inventors

• Yamamoto Toshio
• Hayashi Yuji

Classifications

• H02K1/148

  Sectional cores (H02K1/141 takes precedence) · CPC title

• H02K3/325

  for windings on salient poles, such as claw-shaped poles · CPC title

• H02K2203/12

  Machines characterised by the bobbins for supporting the windings · CPC title

• H02K3/522

  for generally annular cores with salient poles · CPC title

• H02K3/34

  between conductors or between conductor and core, e.g. slot insulation · CPC title