# US 12,009,716 B2 · Armature and manufacturing method thereof

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- Number: US 12,009,716 B2
- Document ID: US12009716B2
- Status: Granted
- Kind: B2
- Application number: 17/699,786
- Filed: 2022-03-21
- Published: 2022-07-07
- Granted: 2024-06-11
- Earliest claimed: 2019-09-19
- Assignees: Denso Corporation
- Applicants: Denso Corporation
- Inventors: Yuki Takahashi
- Web page: https://patentgrep.com/patent/US12009716B2

## CPC

- H02K 1/16: Stator cores with slots for windings
- H02K 3/40: for high voltage, e.g. affording protection against corona discharges
- H02K 1/2766: {having a flux concentration effect}
- H02K 1/278: Surface mounted magnets; Inset magnets
- H02K 3/14: with transposed conductors, e.g. twisted conductors
- H02K 3/28: Layout of windings or of connections between windings (windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32)
- H02K 3/47: Air-gap windings, i.e. iron-free windings
- H02K 3/522: {for generally annular cores with salient poles}
- H02K 5/1735: {radially supporting the rotary shaft at only one end of the rotor (H02K5/1737 takes precedence)}
- H02K 5/20: with channels or ducts for flow of cooling medium
- H02K 7/14: Structural association with mechanical loads, e.g. with hand-held machine tools or fans (with fan or impeller for cooling the machine H02K9/06)
- H02K 11/33: Drive circuits, e.g. power electronics (H02K11/38 takes precedence)
- H02K 15/105: {to the windings}
- H02K 21/14: with magnets rotating within the armatures
- H02K 21/22: with magnets rotating around the armatures, e.g. flywheel magnetos
- H02K 21/26: with rotating armatures and stationary magnets
- H02K 2203/09: Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations
- H02K 2213/03: Machines characterised by numerical values, ranges, mathematical expressions or similar information
- H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53})

## Abstract

An armature is provided with an armature winding, an armature core and a first and second insulation sheets. The first insulation sheet is arranged to sequentially pass through a field magnet side of a first phase conductor, a portion between the first phase conductor and a second phase conductor, an armature core side of the second phase conductor and a third phase conductor and a portion between the third phase conductor and the first phase conductor. The second insulation sheet is arranged to sequentially pass through a portion opposite to the first phase conductor with respect to the first insulation sheet, a field magnet side of the second conductor, a portion between the second phase conductor and the third phase conductor, a portion between the third phase conductor and the first insulation sheet and a portion between the third phase conductor and the first insulation sheet.

## Claims

### Claim 1

An armature adapted to a rotating electric machine provided with a field magnet including a plurality of magnetic poles having alternating polarities in a circumferential direction, the armature being disposed facing the field magnet, the armature comprising:
a three-phase armature winding; and
an armature core disposed opposite to the field magnet in a radial direction with the three-phase armature winding interposed therebetween,
wherein
the armature winding includes conductors arranged in the circumferential direction at predetermined intervals in the order of a first phase, a second phase and a third phase;
a first insulation sheet is arranged to sequentially pass through a field magnet side with respect to a first conductor corresponding to the first phase in a radial direction, a portion between the first conductor and a second conductor corresponding to the second phase, an armature core side with respect to the second conductor and a third conductor corresponding to the third phase in the radial direction and a portion between the third conductor and the first conductor; and
a second insulation sheet is arranged to sequentially pass through a portion opposite to the first conductor with respect to the first insulation sheet in the radial direction, a field magnet side with respect to the second conductor in the radial direction, a portion between the second conductor and the third conductor, a portion between the third conductor and the first insulation sheet in the radial direction and a portion between the third conductor and the first insulation sheet in the circumferential direction.

### Claim 2 (depends on 1)

The armature according to claim 1, wherein
the armature is provided with a third insulation sheet interposed between the armature core, and the first conductor and the first insulation sheet;
a distance in the radial direction from a circumferential surface in a field magnet side of each of the first conductor, the second conductor and the third conductor to the armature core is made to be uniform in a state where a total thickness dimension at a portion positioned between the third conductor and the armature core in the first insulation sheet, the second insulation sheet and the third insulation sheet, a total thickness dimension at a portion positioned between the second conductor and the armature core in the second insulation sheet and the third insulation sheet, and a total thickness dimension at a portion positioned between the first conductor and the armature core in the third insulation sheet are uniform.

### Claim 3

A manufacturing method of an armature adapted to a rotating electric machine provided with a field magnet including a plurality of magnetic poles having alternating polarities in a circumferential direction, the armature being disposed facing the field magnet, the armature comprising a three-phase armature winding and an armature core disposed opposite to the field magnet in a radial direction with the three-phase armature winding interposed therebetween,
the manufacturing method of the armature comprising:
a process for producing a first assembly by arranging a first conductor corresponding to a first phase on a first surface of a first insulation sheet with intervals therebetween;
a process for producing a second assembly by arranging a third conductor corresponding to a third phase on a first surface of a second insulation sheet with intervals therebetween;
a process for disposing a second conductor corresponding to a second phase to be adjacent to the first conductor via the first insulation sheet on a second surface of the first insulation sheet that constitutes the first assembly;
a process for producing a laminate between the first assembly in which the second conductor is disposed and the second assembly such that the second conductor is positioned to be adjacent to the third conductor via the second insulation sheet;
a process for producing the armature winding by making the laminate rounded to be molded in an annular shape; and
a process for producing the armature by assembling the armature winding to the armature core.

### Claim 4 (depends on 3)

The manufacturing method according to claim 3 includes a process wherein
the armature winding is assembled to the armature core in a state where the third insulation sheet is interposed between the first conductor and the first insulation sheet in the process for producing the armature;
the armature is pressed from a field magnet side such that a distance in the radial direction from a circumferential surface in a field magnet side of each of the first conductor, the second conductor and the third conductor to the armature core is made to be uniform, thereby making a total thickness dimension at a portion positioned between the third conductor and the armature core in the first insulation sheet, the second insulation sheet and the third insulation sheet, a total thickness dimension at a portion positioned between the second conductor and the armature core in the second insulation sheet and the third insulation sheet, and a total thickness dimension at a portion positioned between the first conductor and the armature core in the third insulation sheet to be uniform.