Coil assembly, armature and rotating electric machine

Patent metadata

Field	Value
Publication number	US-2025309719-A1
Application number	US-202519232361-A
Country	US
Kind code	A1
Filing date	Jun 9, 2025
Priority date	Dec 12, 2022
Publication date	Oct 2, 2025
Grant date	—

Abstract

A coil assembly includes band members and a plurality of coil units. The band members are formed of an electrically-insulative material into a sheet shape extending in a circumferential direction, and are laminated in layers in a radial direction. The coil units are formed of an electroconductive material on each of the band members, and have a plurality of electrical conductor portions arranged in alignment with one another along the circumferential direction. The electrical conductor portions formed on the band member of a first layer and the electrical conductor portions formed on the band member of a second layer are arranged alternately along the circumferential direction. Moreover, the electrical conductor portions formed on the band member of the first layer and the electrical conductor portions formed on the band member of the second layer overlap one another in the circumferential direction.

First claim

What is claimed is:

1 . A coil assembly comprising:
sheet-shaped members formed of an electrically-insulative material into a sheet shape extending in a circumferential direction, the sheet-shaped members being laminated in layers in a radial direction; and a plurality of coil units formed of an electroconductive material on each of the sheet-shaped members and having a plurality of electrical conductor portions arranged in alignment with one another along the circumferential direction, wherein the electrical conductor portions formed on the sheet-shaped member of a first layer and the electrical conductor portions formed on the sheet-shaped member of a second layer are arranged alternately along the circumferential direction, and the electrical conductor portions formed on the sheet-shaped member of the first layer and the electrical conductor portions formed on the sheet-shaped member of the second layer overlap one another in the circumferential direction.

2 . The coil assembly as set forth in claim 1 , wherein
the first layer and the second layer are adjacent to each other in the radial direction, and a pattern of the coil units formed on the sheet-shaped member of the first layer matches a pattern of the coil units formed on the sheet-shaped member of the second layer.

3 . The coil assembly as set forth in claim 1 , wherein
the first layer and the second layer are adjacent to each other in the radial direction, a circumferential width of each of the electrical conductor portions formed on the sheet-shaped member of the first layer gradually decreases toward the sheet-shaped member of the second layer, and a circumferential width of each of the electrical conductor portions formed on the sheet-shaped member of the second layer gradually decreases toward the sheet-shaped member of the first layer.

4 . The coil assembly as set forth in claim 1 , further comprising a plurality of magnetic portions formed of a soft-magnetic material on each of the sheet-shaped members and arranged in alignment with one another along the circumferential direction.

5 . The coil assembly as set forth in claim 1 , wherein
the sheet-shaped members comprise the sheet-shaped member of the first layer and the sheet-shaped members of the other layers which are located radially outside the sheet-shaped member of the first layer, and circumferential widths of the electrical conductor portions gradually increase from the sheet-shaped member of the first layer to the sheet-shaped members of the other layers.

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

7 . The armature as set forth in claim 6 , further comprising an armature core formed of a soft-magnetic material into an annular shape, wherein
the coil assembly is arranged along the armature core, and the electrical conductor portions formed on the sheet-shaped member of one of the layers which is opposed to the armature core are recess-protrusion-fitted to the armature core.

8 . An armature comprising:
the coil assembly as set forth in claim 1 ; and an armature core formed of a soft-magnetic material into an annular shape, wherein the coil assembly is arranged along the armature core, the electrical conductor portions formed on the sheet-shaped member of one of the layers which is opposed to the armature core are recess-protrusion-fitted to protrusions formed in the armature core, and a circumferential width of each of the electrical conductor portions facing and recess-protrusion-fitted to the armature core is set to be less than a circumferential width of each of the protrusions of the armature core.

9 . 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 6 , and the other of the stator and the rotor has a magnet arranged to face the coil assembly in the radial direction or in an axial direction.

10 . The rotating electric machine as set forth in claim 9 , wherein
for each of the electrical conductor portions, a dimension of the electrical conductor portion in the radial direction, in which the coil assembly and the magnet face each other, is defined as a thickness of the electrical conductor portion, and for each radially-adjacent pair of the layers, the thickness of each of the electrical conductor portions formed on the sheet-shaped member of one of the pair of the layers which is located closer to the magnet is set to be less than the thickness of each of the electrical conductor portions formed on the sheet-shaped member of the other of the pair of the layers which is located further from the magnet.

Assignees

• Denso Corp

Inventors

• Tateishi Yusuke
• Makita Shinji
• Koide Keisuke
• Hayashi Yuji

Classifications

• H02K3/47

  Air-gap windings, i.e. iron-free windings · CPC title

• H02K2203/09

  Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations · CPC title

• H02K3/26

  consisting of printed conductors · CPC title

• 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