# US 12,184,134 B2 · Hairpin type stator coil forming method

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- Number: US 12,184,134 B2
- Document ID: US12184134B2
- Status: Granted
- Kind: B2
- Application number: 17/934,930
- Filed: 2022-09-23
- Published: 2023-01-12
- Granted: 2024-12-31
- Earliest claimed: 2019-10-07
- Assignees: Hyundai Motor Company; Kia Motors Corporation
- Applicants: Hyundai Motor Company; Kia Corporation
- Inventors: Seungkyu Jang
- Web page: https://patentgrep.com/patent/US12184134B2

## CPC

- H02K 15/0421: and consisting of single conductors, e.g. hairpins
- B21F 1/004: {by means of press-type tooling}
- Y02T 10/64: Electric machine technologies in electromobility
- H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53})
- B21F: WORKING OR PROCESSING OF METAL WIRE (rolling of metal wire B21B1/16; by drawing, auxiliary operations used in connection with metal-working without essentially removing material B21C)
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

In an embodiment a method includes cutting a material coil by a predetermined length, forming a vertex and inclined portions on the material coil, loading the vertex and the inclined portion so as to be interposed between an upper mold and a lower mold, forming the vertex into a front/rear bent portion so that the inclined portions are positioned on different lines based on the vertex by combining the upper and lower molds, loading ends of the inclined portions so as to be interposed between clamping pins and rotating a clamping part so that the inclined portions are rounded in front and rear directions.

## Claims

### Claim 1

A method for forming a hairpin type of stator coil, the method comprising:
cutting a material coil to a predetermined length;
forming a vertex and inclined portions on the material coil;
loading the vertex and the inclined portions so as to be interposed between an upper mold and a lower mold;
forming the inclined portions into a front/rear bent portion so that the inclined portions are positioned on different lines based on the vertex by combining the upper and lower molds;
loading ends of the inclined portions into first and second clamping parts so as to be interposed between first and second clamping pins; and
rounding the inclined portions by rotating the first and second clamping parts relative to each other,
wherein cutting the material coil and forming the vertex and the inclined portions comprise:
entering the material coil into an upper portion of a lower central die;
cutting the material coil using a cutting part disposed at a rear side of an entry direction of the material coil;
forming the vertex and the inclined portions on the material coil along a forming surface by moving a moving bracket downward such that a spring part press-fits the material coil to the forming surface of the lower central die; and
moving the moving bracket further downward so that an upper roller part press-fits the material coil along lower left and right dies.

### Claim 2 (depends on 1)

The method of claim 1, wherein forming the vertex and the inclined portions comprises moving the lower left and right dies in left and right directions to be loaded at a predetermined position when the upper roller part moves downward to press-fit the material coil toward the lower left and right dies.

### Claim 3 (depends on 1)

The method of claim 1,
wherein rotating the first and second clamping parts comprise forming the inclined portions of the material coil to be rounded by rotating the second clamping part in one direction with respect to the first clamping part while the material coil is clamped by the first and second clamping pins.

### Claim 4 (depends on 1)

The method of claim 1, wherein the first clamping part is driven along a guider in a direction closer to or further away from the second clamping part.

### Claim 5 (depends on 1)

The method of claim 1, wherein an amount of the inclined portions being bent is determined according to an angle at which the first clamping part rotates.