EP0096415A1
Expired / Lapsed
EP
⏱️ 0.0 years remaining
Flat coil and method of manufacture thereof
Assignee: Denso Corp
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Filing: 1983-06-07
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Granted: —
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Expires: 2003-06-07
Abstract
Abstract A flat coil for use in a rotary electric machine has an annular row of generally radially extending and circumferentially spaced electrically conductive segments (1) on each annular end face of an electrically insulating base member (2). Each segment has a non-effective section disposed adjacent to the radially inner end of the segment and having a mean thickness greater than that of the remaining sections of the segment to improve the cooling ability of the coil. The segments are formed by punching a blank of thin copper sheet to form therein an annular row of radially extending and circumferentially spaced slits to thereby form an annular row of radially extending and circumferentially spaced segments. Before of after the blank is punched, the blank is subjected to forging, electrolytic plating, electrolyzing treatment or mechanical treatment so that the non-effective section of each segment has a thickness greater than that of the remaining sections. Thereafter, the annular row of segments is secured to an annular end face of the annular base member. A similar another annular row of segments is prepared and secured to the other end face of the annular base member. The segments of the two annular rows are then welded at their radially inner and outer ends to form three separate windings of coil around the base member. The annular rows of the segments are then severed along the outer and inner peripheral edges of the rows to separate the segments from the blanks to thereby complete the flat coil.
Inventors
- 👤 Kenji Kanayama
- 👤 Hidekuni Sugi
- 👤 Saburo Ito
- 👤 Masatoshi Suzuki
Bibliographic Details
Application Number
—
Jurisdiction
EP
Data Source
google_patents
Last Synchronized
2026-11-05 14:57
CPC Classifications
H; H02; H02K; H02K3/00; H02K3/04; H02K3/26
Claims Analysis
Total Claims: 18
Claim 1
Independent Claim
207 words
A flat coil for use in a rotary electric machine having a rotary shaft, said coil comprising a relatively thin annular base of an electrically insulating material having opposite annular end faces and outer and inner peripheral edges, said inner peripheral edge defining a central opening for said shaft, and first and second annular rows of generally radially extending and circumferentially spaced axially thin segments of an electrically conductive material, said first and second annular rows of segments being secured to said annular end faces of said base, the segments of said first and second annular rows having radially outer and inner ends electrically connected adjacent to said outer and inner peripheral edges of said base to form at least one winding extending substantially spirally around said annular base, each of said segments including a non-effective section adjacent to said radially inner end of said segment and an effective section adjacent to and radially outward of said non-effective section, wherein said non-effective section of each segment has a first mean thickness measured in the axial direction of said coil, said effective section has a second mean thickness measured in the axial direction of said coil, and said first mean thickness is greater than said second mean thickness.
Claim 2
Dependent Claim
207 words
A flat coil for use in a rotary electric machine having a rotary shaft, said coil comprising a relatively thin annular base of an electrically insulating material having opposite annular end faces and outer and inner peripheral edges, said inner peripheral edge defining a central opening for said shaft, and first and second annular rows of generally radially extending and circumferentially spaced axially thin segments of an electrically conductive material, said first and second annular rows of segments being secured to said annular end faces of said base, the segments of said first and second annular rows having radially outer and inner ends electrically connected adjacent to said outer and inner peripheral edges of said base to form at least one winding extending substantially spirally around said annular base, each of said segments including a non-effective section adjacent to said radially inner end of said segment and an effective section adjacent to and radially outward of said non-effective section, wherein said non-effective section of each segment has a first mean thickness measured in the axial direction of said coil, said effective section has a second mean thickness measured in the axial direction of said coil, and said first mean thickness is greater than said second mean thickness.
Claim 3
Dependent Claim
28 words
A flat coil according to Claim 1, wherein the thickness of said non-effective section of each segment is gradually increased toward the radially inner end of said segment.
Claim 4
Dependent Claim
28 words
A flat coil according to Claim 1, wherein the thickness of said non-effective section of each segment is substantially uniform throughout the radial length of said non-effective section.
Claim 5
Dependent Claim
50 words
A flat coil according to Claim 1, 2 or 3, wherein each of said segments is generally zig.zag as viewed in the axial direction of said coil and wherein the segments of said first and second annular rows are arranged to form a plurality of separate windings of said coil.
Claim 6
Dependent Claim
24 words
A flat coil according to Claim 4, wherein said segments are made of copper and secured to said base by means of ceramic adhesive.
Claim 7
Dependent Claim
41 words
A flat coil according to Claim 5, wherein each of said segments further includes an additional non-effective section disposed between said effective section and said radially outer end and has a mean thickness not greater than that of said effective section.
Claim 8
Dependent Claim
29 words
A flat coil according to Claim 2, wherein the axial thickness of each segment is graduallyfincreased continuously from a point within said effective section to said radially inner end.
Claim 9
Independent Claim
189 words
A method of manufacturing a flat coil for use in a rotary electric machine, said coil including an annular row of generally radially extending and circumferentially spaced electrically conductive segments on each annular end face of an electrically insulating annular base member, said method including the steps of: preparing a relatively axially thin annular base member of an electrically insulating material; preparing two blanks of an electrically conductive thin sheet metal; forming an annular row of generally radially extending and circumferentially spacaed slits in each of said blanks so that the blank is formed therein with an annular row of generally radially extending and circumferentially spaced segments between respective slits, said annular row of segments having outer and inner diameters substantially equal to those of said annular base member, respectively; forging each blank so that the thickness of the annular row of segments is decreased toward the outer peripheral edge of said annular row of segments; and securing the thus forged annular rows of segments of said blanks to the opposite end faces of said annular base member to form at least one winding around said annular base member.
Claim 10
Independent Claim
189 words
A method of manufacturing a flat coil for use in a rotary electric machine, said coil including an annular row of generally radially extending and circumferentially spaced electrically conductive segments on each annular end face of an electrically insulating annular base member, said method including the steps of: preparing a relatively axially thin annular base member of an electrically insulating material; preparing two blanks of an electrically conductive thin sheet metal; forming an annular row of generally radially extending and circumferentially spacaed slits in each of said blanks so that the blank is formed therein with an annular row of generally radially extending and circumferentially spaced segments between respective slits, said annular row of segments having outer and inner diameters substantially equal to those of said annular base member, respectively; forging each blank so that the thickness of the annular row of segments is decreased toward the outer peripheral edge of said annular row of segments; and securing the thus forged annular rows of segments of said blanks to the opposite end faces of said annular base member to form at least one winding around said annular base member.
Claim 11
Dependent Claim
73 words
A method of manufacturing a flat coil according to Claim 8, wherein, after said forged rows of segments have been secured to said annular base member, the segments of said annular rows are electrically connected one to another at their radially inner and outer ends and, thereafter, the blanks are severed along the radially outer and inner edges of said annular rows of segments to separate them from the rest of each blank.
Claim 12
Independent Claim
231 words
A method of manufacturing a flat coil for use in a rotary electric machine, said coil including an annular row of generally radially extending and circumferentially spaced electrically conductive segments on each annular end face of an electrically insulating annular base member, said method including the steps of: preparing two blanks of an elecrically conductive thin sheet metal each having a substantially uniform thickness; subjecting each of said blanks to one of electrolytic plating and electrolyzing treatment to cause a difference in thickness between a substantially circular central zone of the blank and the remaining zone of said blank so that the thickness is greater in said central zone than in said remaining zone, forming an annular row of generally radially extending and circumferentially spaced slits substantially coaxially with said circular central zone in each of said blanks so that the blank is formed therein with an annular row of generally radially extending and circumferentially spaced segments between respective slits, each segment having its radially inner section disposed within said circular central zone; preparing an annular base member of an electrically insulating material having outer and inner diameters substantially equal to those of the annular row of segments of each blank; and securing the annular rows of segments of said blanks to the opposite end faces of said annular base member to form at least one winding around said base member.
Claim 13
Independent Claim
231 words
A method of manufacturing a flat coil for use in a rotary electric machine, said coil including an annular row of generally radially extending and circumferentially spaced electrically conductive segments on each annular end face of an electrically insulating annular base member, said method including the steps of: preparing two blanks of an elecrically conductive thin sheet metal each having a substantially uniform thickness; subjecting each of said blanks to one of electrolytic plating and electrolyzing treatment to cause a difference in thickness between a substantially circular central zone of the blank and the remaining zone of said blank so that the thickness is greater in said central zone than in said remaining zone, forming an annular row of generally radially extending and circumferentially spaced slits substantially coaxially with said circular central zone in each of said blanks so that the blank is formed therein with an annular row of generally radially extending and circumferentially spaced segments between respective slits, each segment having its radially inner section disposed within said circular central zone; preparing an annular base member of an electrically insulating material having outer and inner diameters substantially equal to those of the annular row of segments of each blank; and securing the annular rows of segments of said blanks to the opposite end faces of said annular base member to form at least one winding around said base member.
Claim 14
Dependent Claim
36 words
A method of manufacturing a flat coil according to Claim 10, wherein said central zone of each blank is subjected to said electrolytic plating treatment to increase the thickness of said blank in said central zone.
Claim 15
Dependent Claim
35 words
A method of manufacturing a flat coil according to Claim 10, wherein said remaining zone of each blank is subjected to said electrolyzing treatment to decrease the thickness of said blank in said remaining zone.
Claim 16
Dependent Claim
62 words
A method of manufacturing a flat coil according to Claim 10, 11 or 12, further including a step of forging each blank to form a substantially annular surface on each side of the blank, said annular surface being disposed between said central and remaining zones and inclined at an angle relative to a plane perpendicular to the axis of said central zone.
Claim 17
Independent Claim
328 words
A method of manufacturing a flat coil for use in a rotary electric machine, said coil including an annular row of generally radially extending and circumferentially spaced electrically conductive segments on each annular end face of an electrically insulating annular base member, each of said segments including a non-effective section adjacent to the radially inner end of the segment, said method including the steps of: preparing two blanks of an electrically conductive thin sheet metal; deciding an annular zone within each blank, said annular zone having outer and inner diameters substantially equal to those of circles on which the radially outer and inner ends of said non-effective section of each of said segments are respectively disposed in said flat coil; deciding an annular row of generally radially extending and circumferentially spaced small areas in said annular zone; cutting said blank along one of the generally radial sides of each of said small areas and also along the two generally circumferentially extending sides of said small area to form a tab integral with said blank along the other generally radial side of said small area; bending each tab about said other radial side of said small area and folding the thus bent tab over the remaining area of said annular zone; forming an annular row of generally radially extending and circumferentially spaced slits in each of said blanks so that the blank is formed therein with an annular row of generally radially extending and circumferentially spaced segments between respective slits and so that each segment includes therein one of the thus folded tabs; and preparing a relatively axially thin annular base member of an electrically insulating material having outer and inner diameters substantially equal to those of the annular row of the thus formed segments each blank; securing the thus formed annular rows of segments of said blanks to the opposite end faces of said annular base member to form at least one winding around said annular base member.
Claim 18
Independent Claim
328 words
A method of manufacturing a flat coil for use in a rotary electric machine, said coil including an annular row of generally radially extending and circumferentially spaced electrically conductive segments on each annular end face of an electrically insulating annular base member, each of said segments including a non-effective section adjacent to the radially inner end of the segment, said method including the steps of: preparing two blanks of an electrically conductive thin sheet metal; deciding an annular zone within each blank, said annular zone having outer and inner diameters substantially equal to those of circles on which the radially outer and inner ends of said non-effective section of each of said segments are respectively disposed in said flat coil; deciding an annular row of generally radially extending and circumferentially spaced small areas in said annular zone; cutting said blank along one of the generally radial sides of each of said small areas and also along the two generally circumferentially extending sides of said small area to form a tab integral with said blank along the other generally radial side of said small area; bending each tab about said other radial side of said small area and folding the thus bent tab over the remaining area of said annular zone; forming an annular row of generally radially extending and circumferentially spaced slits in each of said blanks so that the blank is formed therein with an annular row of generally radially extending and circumferentially spaced segments between respective slits and so that each segment includes therein one of the thus folded tabs; and preparing a relatively axially thin annular base member of an electrically insulating material having outer and inner diameters substantially equal to those of the annular row of the thus formed segments each blank; securing the thus formed annular rows of segments of said blanks to the opposite end faces of said annular base member to form at least one winding around said annular base member.
References Cited (Backward Citations)
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