Laminated core

Patent metadata

Field	Value
Publication number	US-9935505-B2
Application number	US-201214369962-A
Country	US
Kind code	B2
Filing date	Dec 27, 2012
Priority date	Dec 29, 2011
Publication date	Apr 3, 2018
Grant date	Apr 3, 2018

Abstract

The invention relates to a laminated core, preferably a stator laminated core or a rotor laminated core ( 2 ), of an electric machine, in particular an electric fuel pump of a motor vehicle. The laminated core comprises slots ( 6 ), each of which has a slot insulation ( 7 ), and winding wires of at least one electric winding ( 10 ), said wires running in the slots ( 6 ). A plastic encapsulation ( 17 ) encases the laminated core together with the winding wires which run in the slots ( 6 ) at least in some regions. The plastic encapsulation ( 17 ) and the slot insulation ( 7 ) each consist of a thermoplastic, and the plastic of the slot insulation ( 7 ) has a melting point which is equal to, similar to, or lower than the melting point of the plastic of the plastic encapsulation ( 17 ) such that the encapsulation process causes the slot insulation ( 7 ) to melt, thereby bonding the slot insulation ( 7 ) to the plastic encapsulation ( 17 ). The invention further relates to a method for producing a laminated core and to an electric machine.

First claim

What is claimed is:

1. A method for producing an electrical machine, the method comprising:
providing a laminated core, wherein the laminated core has a first end face ( 8 ), a second end face ( 9 ), slots ( 6 ), and winding wires of at least one electrical winding ( 10 ), wherein the winding wires run in the slots ( 6 );
injection molding slot insulations ( 7 ) into the slots ( 6 ), the first end face ( 8 ), and the second end face ( 9 );
after the injection molding step, cooling the slot insulations ( 7 ) such that the slot insulations ( 7 ) at least partially solidify;
after the cooling step, encapsulating the laminated core and the slot insulations ( 7 ) by molding a plastic encapsulation ( 17 ) on the laminated core and the slot insulations ( 7 ); and
during and/or after the encapsulating step, cohesively connecting the slot insulations ( 7 ) and the plastic encapsulation ( 17 ) by virtue of incipient melting of the slot insulations ( 7 ) due to heat and/or pressure from the molding of the plastic encapsulation ( 17 ),
wherein the plastic encapsulation ( 17 ) and the slot insulations ( 7 ) are each composed of a thermoplastic and the plastic of the slot insulations ( 7 ) has a melting point which is equal to or similar to or lower than that of the plastic of the plastic encapsulation ( 17 ).

2. The method as claimed in claim 1 , characterized in that the slot insulations ( 7 ) and the plastic encapsulation ( 17 ) are composed of the same plastic.

3. The method as claimed in claim 1 , characterized in that the encapsulation step is done in such a way that the plastic encapsulation ( 17 ) has a circular-cylindrical casing outer surface ( 18 ).

4. The method as claimed in claim 1 , wherein the laminated core is a laminated stator core or laminated rotor core ( 2 ) of an electric fuel pump of a motor vehicle.

5. The method as claimed in claim 1 , characterized in that the slot insulations ( 7 ) and the plastic encapsulation ( 17 ) are composed at least substantially of polyoxymethylene.

6. The method as claimed in claim 1 , further comprising:
after the cooling step and before the encapsulating step, heating the laminated core and the slot insulations ( 7 ).

7. A method for producing an electrical machine, the method comprising:
providing a laminated core, wherein the laminated core has a first end face ( 8 ), a second end face ( 9 ), slots ( 6 ), and winding wires of at least one electrical winding ( 10 ), wherein the winding wires run in the slots ( 6 );
injection molding slot insulations ( 7 ) into the slots ( 6 ), the first end face ( 8 ), and the second end face ( 9 ), wherein a surface ( 20 ) of a respective slot insulation ( 7 ) of the slot insulations ( 7 ) has at least one of a raised portion ( 19 ) and a recessed portion;
after the injection molding step, cooling the slot insulations ( 7 ) such that the slot insulations ( 7 ) at least partially solidify;
after the cooling step, encapsulating the laminated core and the slot insulations ( 7 ) by molding a plastic encapsulation ( 17 ) on the laminated core and the slot insulations ( 7 );
during the encapsulating step, surrounding the raised portion ( 19 ) of the slot insulations ( 7 ) with the plastic encapsulation ( 17 ) when the at least one of a raised portion ( 19 ) and a recessed portion is a raised portion ( 19 ) or entering the recessed portion of the slot insulations ( 7 ) with the plastic encapsulation ( 17 ) when the at least one of a raised portion ( 19 ) and a recessed portion is a recessed portion; and
during and/or after the encapsulating step, cohesively connecting the slot insulations ( 7 ) and the plastic encapsulation ( 17 ) by virtue of incipient melting of the slot insulations ( 7 ) due to heat and/or pressure from the molding of the plastic encapsulation ( 17 ),
wherein the plastic encapsulation ( 17 ) and the slot insulations ( 7 ) are each composed of a thermoplastic and the plastic of the slot insulations ( 7 ) has a melting point which is equal to or similar to or lower than that of the plastic of the plastic encapsulation ( 17 ).

8. The method as claimed in claim 7 , wherein the slot insulations ( 7 ) and the plastic encapsulation ( 17 ) are composed of the same plastic.

9. The method as claimed in claim 7 , wherein the at least one of a raised portion ( 19 ) and a recessed portion is a recessed portion.

10. The method as claimed in claim 7 , wherein the at least one of a raised portion ( 19 ) and a recessed portion is a raised portion ( 19 ).

11. The method as claimed in claim 10 , wherein the raised portion ( 19 ) is in the form of a longitudinal rib or transverse rib ( 21 ).

12. The method as claimed in claim 11 , wherein the ribs ( 21 ) are formed during the injection molding step such that the rib ( 21 ) is integrally formed with the respective slot insulation ( 7 ).

13. The method as claimed in claim 12 , further comprising:
during the surrounding of the raised portion ( 19 ) step and during the encapsulating step, deforming the rib ( 21 ).

14. The method as claimed in claim 7 , wherein the encapsulation step is formed done in such a way that the plastic encapsulation ( 17 ) has a circular-cylindrical casing outer surface ( 18 ).

15. The method as claimed in claim 7 , further comprising:
after the cooling step and before the encapsulating step, heating the laminated core and the slot insulations ( 7 ).

16. The method as claimed in claim 7 , wherein the laminated core is a laminated stator core or laminated rotor core ( 2 ) of an electric fuel pump of a motor vehicle.

17. The method as claimed in claim 7 , wherein the slot insulations ( 7 ) and the plastic encapsulation ( 17 ) are composed at least substantially of polyoxymethylene.

Assignees

• Bosch Gmbh Robert

Inventors

• Himmel Oliver
• Stucke Ursula
• Nowak Joost
• Buchholz Ingo
• Spinner Alexis

Classifications

• H02K1/26

  Rotor cores with slots for windings · CPC title

• H02K1/16

  Stator cores with slots for windings · CPC title

• B29C45/14639

  for obtaining an insulating effect, e.g. for electrical components · CPC title

• B29K2059/00

  Use of polyacetals {, e.g. POM, i.e. polyoxymethylene or derivatives thereof}, as moulding material · CPC title

• H02K15/105

  to the windings · CPC title