Coil component for electric machine of motor vehicle and method for producing coil component

Abstract

The invention relates to a coil component (10) for an electric machine of a motor vehicle, comprising a carrier (12) having a plurality of grooves (14) which are distributed in the circumferential direction (U) of the carrier (12) and extend in the axial direction; a plurality of hairpins (16), which are at least partially arranged in the grooves (14); and at least one insulating element arranged in one of the grooves (14), by means of which the hairpin (16) arranged in this groove (14) is electrically insulated from a groove wall of the carrier (12) defining the groove (14), the insulating element (18, 30, 36) being supported on the groove wall of the carrier (12) by means of a wedge geometry (28), in this way, a force acting on the wedge geometry (28) in the axial direction (A) is converted into a force acting in the circumferential direction (U), by means of which the insulating element (18, 30, 36) is pressed against the hairpin (16) in the circumferential direction (U).

Description

Technical Field

[0001] The invention relates to a coil component for a motor vehicle electric motor and a method for producing a coil component for a motor vehicle electric motor. Background Art

[0002] A coil component for an electric machine is known from WO 2022 / 033627 A1, which comprises a carrier and a coil winding at least partially accommodated in the carrier. The carrier has an annular region with a plurality of slots distributed in the circumferential direction, wherein a plurality of winding segments of the coil winding are accommodated in each slot. In at least one slot, an insulating layer is arranged between the carrier and the winding segment and extends beyond the winding segment toward the radial opening of the at least one slot with two extension segments. In the at least one slot provided with an insulating layer, a closing element is accommodated in the carrier toward the radial opening, wherein the two extension segments are constructed and arranged in such a way that the closing element is spaced apart from the carrier by the extension segments.

[0003] It is known to insulate the stator slots with a flat insulating material. After the winding is installed, it is impregnated with a synthetic resin in order to fix it in the stator, improve the heat transfer to the laminated core and increase the resistance to partial discharges. However, there is an incompatibility between the varnish insulation of the stator winding and this impregnation resin. In the case of drip impregnation, the impregnation resin can fall onto the winding heads of the stator winding. This can lead to failure of the varnish insulation of the winding there. Summary of the invention

[0004] The object of the present invention is to provide a solution by means of which the coils of a coil component can be particularly well electrically insulated relative to a carrier and failure of the lacquer insulation of the coils can be avoided.

[0005] According to the present invention, this object is solved by the technical solution of the independent claim. Other possible design solutions of the present invention are disclosed in the dependent claims, the specification and the drawings. The features, advantages and possible design solutions set forth in the scope of the specification for one of the technical solutions of the independent claims can at least be similarly regarded as the features, advantages and advantageous design solutions of the corresponding technical solutions of the other independent claims and each possible combination of the technical solutions of the independent claims.

[0006] The present invention relates to a coil component for a motor vehicle. The coil component can be a rotor or a stator for a motor vehicle. The motor vehicle is particularly a traction machine, by means of which a motor vehicle can be electrically driven. The coil component includes a carrier having a plurality of slots extending in an axial direction and distributed along the circumferential direction of the carrier. The carrier can, for example, include a stack of laminations consisting of a plurality of laminations stacked one on another along a stacking direction or be manufactured in one piece, for example, within the scope of a sintering process. The coil component also includes a plurality of hairpins, which are at least partially arranged in the slots. These hairpins can also be referred to as plug-in coils. These hairpins can be U-shaped enameled copper flat wires, which are inserted into the slots of the carrier. Alternatively, the hairpins can be configured as I-pins and thus as straight copper flat wire elements. All the hairpins of the coil component form a coil of the coil component. This means that the coil includes all the hairpins of the coil component, which are inserted into the slots of the carrier. In particular, at least one hairpin is arranged in each slot of the carrier. In particular, a plurality of hairpins are arranged in each slot of the carrier.

[0007] The coil component further comprises at least one insulating element arranged in one of the slots, by means of which the hairpin pin arranged in the slot is electrically insulated relative to the slot wall of the carrier defining the slot. In particular, the coil component comprises a plurality of insulating elements, at least one insulating element being arranged in each slot of the carrier, by means of which the hairpin arranged in the slot is insulated relative to the slot wall of the carrier defining the slot. In order to ensure a particularly good heat transfer provision from the hairpin to the carrier, the insulating element is supported on the slot wall of the carrier by a wedge-shaped geometry. By means of the wedge-shaped geometry, the force acting on the wedge-shaped geometry in the axial direction of the carrier is converted into a force acting in the circumferential direction of the carrier, by means of which the insulating element is pressed against the hairpin in the circumferential direction. The axial direction of the carrier in particular coincides with the rotation axis of the rotor or the center axis of the stator as the coil component. The circumferential direction coincides with the rotation direction of the rotor relative to the stator in the electric machine. Therefore, the at least one insulating element is clamped in the slot by the wedge-shaped geometry, so that the at least one insulating element is particularly close to and in particular flat against the hairpin. As a result, a particularly good heat dissipation from the hairpin via the insulating element to the carrier can be achieved. This particularly good heat transfer can cool the hairpin particularly well, so that overheating of the hairpin can be avoided particularly well. As a result, the motor can be operated particularly efficiently and with particularly high power.

[0008] In one possible embodiment of the invention, it is provided that the insulating element has a wedge-shaped geometry, so that the two side surfaces of the insulating element converge at an acute angle. In other words, the wedge-shaped geometry of the insulating element comprises a first surface and a second surface oriented obliquely relative to the first surface, which approach each other in the axial direction and abut each other in particular at a tapered edge. Since the insulating element itself has a wedge-shaped geometry, particularly few components are required in the coil component in order to electrically insulate the hairpin relative to the carrier on the one hand and to bring the insulating element particularly close to the hairpin on the other hand. The coil component can thus be manufactured particularly simply.

[0009] In a possible extension of the present invention, it is provided that the insulating element has a U-shaped cross section. Here, in a state where the insulating element is inserted into the slot of the carrier in the axial direction, in particular in a section of the insulating element extending perpendicularly to the axial direction, the cross section is U-shaped. By means of this U-shaped cross section of the insulating element, at least one hairpin arranged in the slot, in particular all hairpins arranged in the slot, can be electrically insulated at least with respect to three side surfaces by means of the insulating element. Thus, the hairpin can be electrically insulated with respect to the carrier over a particularly large area by means of the insulating element.

[0010] In another possible embodiment of the invention, it is provided that a plurality of insulating elements are arranged one above the other in the axial direction in a groove and are partially inserted into one another, whereby the respective insulating elements with their respective wedge-shaped geometries abut one another. Due to the abutting wedge-shaped geometries of the insulating elements arranged in a common groove, the insulating elements can be clamped against one another in the groove, so that one of the insulating elements presses another insulating element in the same groove particularly firmly against a hairpin arranged in the groove.

[0011] In this case, it can be provided in particular that two insulating elements are arranged in the groove, the respective legs of the U-shaped cross section of the two insulating elements being oriented toward one another, whereby the insulating elements jointly surround a channel extending in the axial direction and through which the hairpin extends. This means that the hairpin is inserted into a channel, which extends with its longitudinal extension in the axial direction of the carrier, whereby the hairpin arranged in the common groove is reliably electrically insulated from the carrier on the circumferential side by the two insulating elements. In other words, the respective open sides of the U-shaped cross section of the insulating elements are oriented toward one another, whereby the legs and the back of the insulating elements jointly define the channel on the circumferential side.

[0012] In another possible design of the present invention, it can be provided that the insulating element has at least one straight section extending in the axial direction with a constant wall thickness and at least one wedge-shaped geometry connected to the straight section in the axial direction. The insulating element can, for example, have a straight section in the middle when it is inserted into the slot and have a wedge-shaped geometry connected to the straight section in the axial direction upward and another wedge-shaped geometry connected to the straight section in the axial direction downward. Thus, the insulating element can be wedged with another insulating element not only upward in the axial direction but also downward in the axial direction. Therefore, in the slot, multiple insulating elements can be arranged one above the other in the axial direction and wedged with each other by their corresponding wedge-shaped geometries. This makes it possible to injection mold the corresponding insulating elements particularly simply because these insulating elements can be manufactured with a length that is particularly simple to manufacture and particularly stable in the injection molding range. Simply arrange so many insulating elements one above the other in the axial direction until the hairpin arranged in the slot is electrically insulated relative to the carrier over the entire length of the slot by the corresponding insulating elements. Therefore, on the one hand, an insulating element with particularly large stability can be manufactured particularly simply and on the other hand, a particularly reliable electrical insulation of the hairpin relative to the carrier can be achieved.

[0013] In another possible design of the present invention, it is provided that at least one insulating element has a stop portion, which can stop on the end face of the carrier and predetermine the axial final position of the insulating element. If the coil component has a plurality of insulating elements, at least one of these insulating elements or at most two of them can have the stop portion, and the first insulating element of the insulating elements stops on the first end face of the carrier with the stop portion and the second insulating element stops on the second end face of the carrier opposite to the first end face with its stop portion. When the stop portion stops on the end face of the carrier, the insulating element with the stop portion ensures that the hairpin in the corresponding groove is completely electrically insulated from the carrier up to the end face at the end of the groove where the insulating element is located. This ensures that the hairpin arranged in the groove is completely electrically insulated from the carrier up to the edge of the groove and that the insulating element does not slide into the groove and thus electrical contact between the hairpin and the carrier occurs at the outer edge of the groove.

[0014] In a possible extension of the present invention, it is provided that the insulating element is pressed onto the hairpin by means of a slot insulating wedge separated therefrom and having a wedge-shaped geometry. This means that the insulating element does not have a wedge-shaped geometry. For example, the insulating element can be slot insulating paper. The slot insulating paper can have a constant thickness over its entire height extending in the axial direction. The slot insulating paper can be pressed onto the hairpin by means of a slot insulating wedge having a wedge-shaped geometry. For this purpose, the slot insulating wedge is inserted and clamped between the carrier and the insulating element, whereby the insulating element directly rests on and is in particular pressed onto the hairpin. Therefore, the insulation of the hairpin can be achieved particularly simply by means of the slot insulating paper, whereby it is ensured that the slot insulating paper rests on the hairpin over a large area and that the gap between the slot insulating paper and the carrier is filled by means of the at least one slot insulating wedge. Thus, it is possible to dispense with the need to cast the gap between the slot insulating paper and the carrier with impregnating resin.

[0015] In order to facilitate the insertion of the wedge-shaped geometry between the carrier and the hairpin, the carrier may have a lead-in bevel.

[0016] The invention also relates to a method for producing a coil component for an electric motor of a motor vehicle. The motor comprises a carrier having a plurality of slots extending in an axial direction and distributed in the circumferential direction of the carrier. The coil component can be, for example, a rotor or a stator of the motor. Within the scope of the method, in particular, a coil component as already described in conjunction with the coil component according to the invention is produced. In the method, it is provided that a plurality of hairpins and at least one insulating element are at least partially arranged in the slots, by means of which the hairpins are electrically insulated relative to the slot walls of the carrier defining the slots. In particular, it is provided in the method that a plurality of hairpins and at least one insulating element are inserted into each slot of the carrier. In the method, it is also provided that the at least one insulating element is supported on the slot wall of the carrier by a wedge-shaped geometry, thereby converting the force acting on the wedge-shaped geometry in the axial direction into a force acting in the circumferential direction, by means of which the insulating element is pressed against the hairpin in the circumferential direction. By pressing the insulating element against the hairpin, a particularly large contact surface is provided between the hairpin and the insulating element, whereby heat can be transferred particularly effectively from the hairpin to the carrier through the insulating element. The hairpin can thereby be cooled particularly effectively. It is possible that the insulating element has a wedge-shaped geometry or that the insulating element does not have a wedge-shaped geometry and that a slot insulating wedge with a wedge-shaped geometry is additionally arranged in the slot, by means of which the insulating element is pressed onto the hairpin. This method makes it possible to dispense with the use of an impregnation resin for electrically insulating the hairpin relative to the carrier. The risk of failure of the lacquer insulation of the coil due to contact between the impregnation resin and the lacquer insulation can thus be eliminated. A particularly long service life of the coil component can thereby be achieved.

[0017] In the coil component or the method according to the invention, impregnation resin is omitted and instead a multi-part plastic slot insulation with a wedge-shaped wall longitudinal profile is used which clamps the hairpins by being inserted into one another and thus fixes them in a carrier, in particular a laminated core.

[0018] Other features of the invention can be derived from the claims, the drawings and the description of the drawings. The features and feature combinations mentioned above in the description and the features and feature combinations shown below in the description of the drawings and / or in the drawings alone can be used not only in the respectively given combination but also in other combinations or alone without departing from the scope of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The attached pictures are as follows:

[0020] Figure 1 A schematic cross-sectional view showing a portion of a motor coil component according to a first embodiment;

[0021] Figure 2 Show according to Figure 1 An exploded view of a hairpin disposed in a slot of a motor carrier and two insulating elements disposed in the slot according to an embodiment of the present invention;

[0022] Figure 3 A schematic perspective view showing a portion of a coil member according to a first embodiment;

[0023] Figure 4 A schematic cross-sectional view showing a portion of a coil member according to a second embodiment;

[0024] Figure 5 An exploded view showing a portion of a coil member of a second embodiment;

[0025] Figure 6 A schematic cross-sectional view showing a portion of a coil member according to a third embodiment; and

[0026] Figure 7 An exploded view showing a portion of a coil component according to a third embodiment. DETAILED DESCRIPTION

[0027] In the figures, identical elements and elements having the same function are provided with the same reference symbols.

[0028] The drawings show a coil component 10 for a motor vehicle electric motor. The electric motor is in particular a traction machine for a motor vehicle, by means of which the motor vehicle can be driven with electrical energy. In the present case, the coil component 10 is the stator of the electric motor. The stator is in particular a hairpin stator.

[0029] This hairpin stator includes a carrier 12, which is currently configured as a lamination stack. The carrier 12 has a plurality of slots 14 distributed along the circumferential direction U of the carrier 12, and these slots extend along the axial direction A of the carrier 12 with their longitudinal extension direction. The coil component 10 also includes a plurality of hairpins 16, which are corresponding phase lines and are inserted into the slots 14 of the carrier 12. All hairpins 16 form a coil. Each hairpin 16 extends over the entire length of the assigned slot 14 extending along the axial direction A. At present, a plurality of hairpins 16 are arranged side by side in each slot 14. Here, these hairpins 16 are arranged in a line one after another along the radial direction R of the carrier 12. The radial direction R is perpendicular to the axial direction A. In order to electrically insulate the hairpins 16 arranged in the slots 14 of the carrier 12 relative to the carrier 12, each slot 14 is provided with at least one insulating element or each slot 14 is provided with a plurality of insulating elements, by means of which the hairpins 16 are electrically insulated relative to the carrier 12.

[0030] exist Figure 1 , 2 3 and 4 show a first embodiment of the coil component 10, in Figure 4 and 5 The coil component 10 of the second embodiment is shown in FIG. Figure 6 and 7 , a coil component 10 of a third embodiment is shown. The differences between these embodiments lie in the design of the corresponding insulating element. All embodiments have in common that the corresponding insulating element is clamped on the carrier 12 by at least one wedge-shaped geometric structure, whereby the insulating element is particularly close to and in particular abuts on the hairpin 16 over a particularly large area. As a result, a particularly good heat transfer from the hairpin 16 to the corresponding insulating element can be achieved, so that the hairpin 16 can also be cooled particularly well during operation. Therefore, all embodiments have in common that at least one insulating element is provided in each slot 14, by means of which the hairpin 16 arranged in the slot 14 is electrically insulated relative to the slot wall of the carrier 12 that defines the slot 14, wherein the insulating element is supported on the slot wall of the carrier 12 by the wedge-shaped geometric structure. As a result, the force acting on the wedge-shaped geometric structure in the axial direction A is at least partially converted into a force acting in the circumferential direction U, by means of which the insulating element is pressed against the hairpin 16 in the circumferential direction U. Compensation for tolerances can be achieved by pressing in the circumferential direction.

[0031] exist Figures 1 to 5 The embodiments shown in have in common that the at least one insulating element has a wedge-shaped geometry. Figure 6 and 7In the third embodiment of the invention shown in , the insulating element does not have a wedge-shaped geometry, but at least one slot insulating wedge 38 having a wedge-shaped geometry and constructed separately from the insulating element is arranged in the corresponding slot 14, with the help of which the insulating element is pressed onto the hairpin 16.

[0032] exist Figures 1 to 3 In the first embodiment of the coil component 10 shown in FIG. 1 , it is provided that the coil component 10 has two first insulating elements 18. The first insulating element 18 has a U-shape in a cross section extending perpendicularly to the axial direction A. Figure 3 It can be seen particularly clearly in the figure that in the groove 14 provided with the first insulating elements 18, the two first insulating elements 18 are oriented with their respective legs of the U-shaped cross section facing each other. It follows from this that the two first insulating elements 18 together surround the channel 20 extending in the axial direction A in the groove 14 on the circumferential side. All hairpins 16 assigned to the groove 14 are arranged in the channel 20. The hairpins 16 arranged in the channel 20 are therefore completely electrically insulated on the circumferential side by the two first insulating elements 18 from the groove wall of the carrier 12 which delimits the respective groove 14. As a result, an electrically conductive contact between the hairpins 16 and the carrier 12 can be particularly reliably avoided.

[0033] As in Figure 1 It can be seen particularly clearly in FIG. 1 that the first insulating element 18 has a flange 22 at one end thereof, by which a stop 24 is provided. The flange 22 abuts against a first end face 26 of the carrier 12, whereby the stop 24 abuts against the first end face 26 of the carrier 12. By causing the stop 24 to abut against the first end face 26 of the carrier 12, the axial end position of the first insulating element 18 in the groove 14 is predetermined. Figure 2 It can be seen that the two first insulating elements 18 of the first embodiment each have a collar 22 with a stop 24. The other first insulating element 18 can rest with its collar 22 on a second end face of the carrier 12, which is opposite the first end face 26 and is not shown in the figures, whereby the other first insulating element 18 stops with its stop 24 on the second end face and thus also predetermines the axial end position of the other first insulating element 18. The predetermined axial end position of the first insulating element 18 or the contact of the collar 22 of the first insulating element 18 on the opposite end face of the carrier 12 ensures that the hairpin 16 in the corresponding groove 14 is electrically insulated from the carrier 12 by means of the first insulating element 18 over the entire length of the groove 14 in the axial direction A by means of the channel 20 formed by the first insulating element 18. The risk of a current flow between the hairpin 16 and the carrier 12 can thus be kept particularly low.

[0034] In order to ensure that the at least one first insulating element 18 rests particularly flatly on the hairpin 16 and to avoid or reduce air gaps between the hairpin 16 and the groove walls of the carrier 12 that define the groove 14, the first insulating elements 18 each have a wedge-shaped geometry 28. Figure 1 It can be seen that the upper first insulation element 18 in the axial direction A can have a wedge-shaped inner contour, while the lower first insulation element 18 in the axial direction A has a wedge-shaped outer contour. The wedge-shaped inner contour of the upper first insulation element 18 rests on the wedge-shaped outer contour of the lower first insulation element 18. When a force acting in the axial direction A on one of the first insulation elements 18 acts in the direction of the other first insulation element 18, the wedge-shaped geometries of the first insulation elements 18 move along one another. As a result, the force acting in the axial direction A is at least partially converted into a force acting in the circumferential direction by the wedge-shaped geometry by the ramp principle, thereby pressing the first insulation elements 18 against one another and against the groove wall and the hairpin 16. As a result, the air gap in the groove 14 filled with the hairpin 16 can be reduced or, in particular, completely eliminated. A particularly good heat transfer from the hairpin 16 to the carrier 12 is thereby achieved.

[0035] Therefore, in a first embodiment, two first insulating elements 18 are used, which are in the form of two U-shaped sleeves and have a wedge-shaped geometry on the inner contour or on the outer contour. The axial force is converted into a tangential force by the wedge-shaped geometry. As a result, when installed in the axial end position, a surface pressure is generated between the wedge-shaped area of ​​the first insulating element 18, in particular the carrier 12 configured as a laminated core, and the phase conductor and thus the hairpin 16. In the corresponding first insulating element 18, the wedge-shaped geometry can be achieved by reducing the wall thickness in the extension of the axial direction A and, if necessary, additionally by reducing the wall thickness in the radial direction R. Therefore, the first insulating elements 18 can be wedged into each other in the circumferential direction U. The insulating elements of the first and second embodiments are currently made of electrically insulating plastic.

[0036] In order to install the coil component 10, in a first embodiment, a sleeve-shaped first insulating element 18 is inserted into the slot 14 of the carrier 12 in the axial direction A. The tangential dimension between the sleeve and the phase conductor can be adjusted according to the axial position of the sleeve. When installed in the final position, surface pressure is generated between the wedge-shaped area of ​​the first insulating element 18, the laminated stack and the phase conductor, thereby generating high tangential forces. The coil component 10 of the first embodiment can be disassembled again, can be manufactured in a short cycle, does not contain casting resin, has a very high slot filling degree and can achieve the centering of the phase conductor in the slot 14.

[0037] exist Figure 4 and 5In the second embodiment shown in , it is provided that at least one first insulating element 18 and at least one second insulating element 30 are arranged in the groove 14. The first insulating element 18 has a flange 22 that provides a stop 24, thereby predetermining the axial final position of the first insulating element 18. The second insulating element 30 has a straight section 32 extending in the axial direction A and two wedge sections 34, which are respectively connected to the straight section 32 upward and downward in the axial direction A. The wedge sections 34 have a wedge-shaped geometry. In the cross section of the second insulating element 30 extending perpendicularly to the axial direction A, the second insulating element 30 has a U-shaped cross section. In this state where the second insulating element 30 is inserted into the groove 14, the legs of the U-shaped cross section are radially oriented in the same direction as the legs of the U-shaped cross section of the first insulating element 18. This means that the U-shaped cross sections of the first insulating element 18 and the second insulating element 30 point with their openings in the same direction. In a longitudinal section of one of the legs of the U-shaped cross section of the second insulating element 30, which extends in the axial direction A perpendicular to the radial direction R, the longitudinal section has a trapezoidal geometry with opposite sides oriented parallel to one another. This means that in the present case the second insulating element 30 has a constant wall thickness in the straight section 32, while the wall thickness of the second insulating element 30 in the wedge-shaped section 34 tapers toward the respective end (in the present case the upper end in the axial direction A and the lower end in the axial direction A) in order to provide the wedge-shaped geometry.

[0038] In a second embodiment, a plurality of second insulating elements 30 can be arranged one above the other in the corresponding groove 14 in the axial direction A in order to ensure that the hairpin 16 is electrically insulated from the carrier 12 by the respective insulating elements over the entire length of the groove 14 extending in the axial direction A. For example, a first insulating element 18 can be arranged at the top in the groove 14 in the axial direction A, followed by one or more second insulating elements 30 in the axial direction A and the first insulating element 18 can be arranged again below in the axial direction. The respective insulating elements arranged one above the other in the axial direction A rest against each other with their wedge-shaped geometry so that the insulating elements are pressed against each other and against the phase conductor configured as the hairpin 16 and the respective groove wall delimiting the groove 14 by applying an axial force via the ramp principle. The design of the insulation in the groove 14 by means of a plurality of second insulating elements 30 makes it particularly easy to injection mold these second insulating elements 30 and the at least one first insulating element 18, since the length of the respective insulating element extending in the axial direction A can be adjusted for the injection molding process. This means that the length of the insulating elements is selected in such a way that they can be manufactured particularly easily in the injection molding process. As a result, a particularly simple production of the corresponding insulation element and a particularly high stability of the insulation element can be achieved.

[0039] Therefore, in a second embodiment of the coil component 10, it is provided that a trapezoidal slot insulator is used as the second insulating element 30, which is inclined toward the corresponding end face of the carrier 12, in particular the laminated core. A U-shaped sleeve with a wedge-shaped geometry can be arranged on the corresponding end face of the carrier 12, and the U-shaped sleeve is designed similarly to the first insulating element 18 described in conjunction with the first embodiment in terms of its shape. In the second embodiment, when installed in the axial end position, a surface pressure is generated between the wedge-shaped geometry of the slot insulator and the phase conductor.

[0040] In the second embodiment, it is possible to adjust the tangential dimension between the slot wedge and the phase conductor on the end face as a function of the axial position of the slot wedge. Particularly high tangential forces are generated by the surface pressure. Since slot insulation paper is not used in this second embodiment, there is no risk of the slot insulation paper sticking out. The coil component 10 of the second embodiment can be disassembled again particularly easily, does not contain casting resin, can be manufactured in particularly short cycles, has a very high slot filling degree and allows the phase conductor to be centered in the respective slot 14.

[0041] exist Figure 6 and 7 , a third embodiment of the coil component 10 is shown in FIG. 1 , in which the respective hairpin 16 is insulated from the respective slot wall of the carrier 12 defining the associated slot 14 by means of a slot insulating paper 36 as an insulating element. The slot insulating paper 36 extends over the entire height of the slot 14 in the axial direction A, whereby the hairpin 16 arranged in the slot 14 is electrically insulated from the carrier 12 over the entire height of the slot 14. In the present case, the slot insulating paper 36 has a constant wall thickness over its entire extension. In order to ensure that the slot insulating paper 36 is particularly tightly attached to the respective hairpin 16, so as to thereby ensure particularly good heat transfer, respective slot insulating wedges 38 having a wedge-shaped geometry are provided. The slot insulating wedges 38 are respectively inserted into the respective slot 14 between the slot insulating paper 36 and the wall defining the slot 14. This means that the slot insulating wedges 38 not only abut against the slot wall defining the slot 14, but also against the slot insulating paper 36. In these slot insulating wedges 38, the respective side surfaces abutting against the slot insulating paper 36 and the slot wall converge at an acute angle in the axial direction A. The sharp edges of the slot insulating wedges 38 are oriented toward the center of the carrier 12 in the axial direction A. Therefore, by pushing the slot insulating wedges 38 into the slots 14, the slot insulating papers 36 are pressed against the hairpins 16 in the circumferential direction U. In the present case, at least two slot insulating papers 36 are arranged in each slot 14 on the opposite sides of the hairpins 16 in the circumferential direction U. The hairpins 16 are therefore electrically insulated from the carrier 12 on their opposite sides in the circumferential direction U by one slot insulating paper 36 in each case.

[0042] Therefore, in the third embodiment, each slot 14 and each end face of the carrier 12 are provided with two slot insulating wedges 38. The two slot insulating wedges 38 at each end face press the slot insulating paper 36 as the third insulating element onto the phase line of the coil member 10. The axial force when clamping the slot insulating wedges 38 is converted into a tangential force acting in the circumferential direction U. In order to facilitate the insertion of the slot insulating wedges 38 into the corresponding slot 14, the slot 14 may have a corresponding introduction slope 40 for each slot insulating wedge 38 on the corresponding end face of the carrier 12.

[0043] Depending on the axial position of the slot insulating wedge 38, the tangential dimension between the slot insulating wedge 38 and the phase conductor can be adjusted on the corresponding end face of the carrier 12. When installed in the final position, surface pressure is generated between the slot insulating wedge 38, the carrier 12 and thus the laminated stack and the phase conductor, thereby generating particularly high tangential forces in the circumferential direction U. The slot insulating paper 36 does not protrude. The coil component 10 of the third embodiment can be disassembled again particularly easily, does not contain casting resin, can be manufactured in particularly short cycles, has a very high slot filling degree and can achieve centering of the phase conductor in the slot 14.

[0044] In summary, the present invention shows how to use wedge-shaped slot insulation for stator windings of an electric machine.

[0045] Reference numerals list

[0046] 10 Coil components

[0047] 12 Carrier

[0048] 14 slots

[0049] 16 Hairpin

[0050] 18 first insulating element

[0051] 20 channels

[0052] 22 Flange

[0053] 24 Stopper

[0054] 26 first end surface

[0055] 28 Wedge Geometry

[0056] 30 second insulating element

[0057] 32 straight sections

[0058] 34 wedge-shaped segments

[0059] 36 slot insulation paper

[0060] 38 slot insulation wedge

[0061] 40 Lead-in bevel

[0062] A Axial direction

[0063] U Circumferential direction

[0064] R radial direction

Claims

1. A coil component (10) for a motor vehicle motor, the coil component comprising: - a carrier (12) having a plurality of grooves (14) extending in the axial direction and distributed in a circumferential direction (U) of the carrier (12), - a plurality of hairpins (16) which are at least partially arranged in the groove (14), - at least one insulating element arranged in one of the grooves (14), by means of which a hairpin (16) arranged in the groove (14) is electrically insulated relative to a groove wall of the carrier (12) defining the groove (14), wherein the insulating element (18, 30, 36) is supported on the groove wall of the carrier (12) via a wedge-shaped geometry (28), thereby converting a force acting in an axial direction (A) on the wedge-shaped geometry (28) into a force acting in a circumferential direction (U), by means of which the insulating element (18, 30, 36) is pressed against the hairpin (16) in the circumferential direction (U).

2. The coil component (10) according to claim 1, characterized in that: The insulating element (18, 30) has a wedge-shaped geometry (28), such that two side faces of the insulating element (18, 30) converge at an acute angle.

3. The coil component (10) according to claim 1 or 2, characterized in that: The insulating element (18, 30) has a U-shaped cross section.

4. The coil component (10) according to claim 2 or 3, characterized in that: In a groove (14), a plurality of insulating elements (18, 30) are arranged one above the other in an axial direction (A) and are partially inserted into one another, whereby the respective insulating elements (18, 30) rest against one another with their respective wedge-shaped geometries (28).

5. The coil component (10) according to claim 3 and 4, characterized in that Two insulating elements (18) are arranged in the groove (14), the respective legs of the U-shaped cross section of the two insulating elements being oriented toward each other, whereby the insulating elements (18) jointly surround a channel (20) extending in the axial direction (A) and through which the hairpin (16) extends.

6. The coil component (10) according to claim 2 or claims 3 to 5 based on claim 2, characterized in that: The insulating element (30) has at least one straight section (32) extending in an axial direction (A) and having a constant wall thickness and at least one wedge-shaped geometry (28) adjoining the straight section (32) in the axial direction (A).

7. The coil member (10) according to any one of the preceding claims, characterized in that The insulating element (18) has a stop (24) which can abut against an end face (26) of the carrier (12) and which specifies an axial end position of the insulating element (18).

8. The coil component (10) according to claim 1, characterized in that: The insulating element (36) is pressed onto the hairpin (16) by means of a separate slot insulating wedge (38) having a wedge-shaped geometry (28).

9. A method for producing a coil component (10) for a motor vehicle electric motor, the coil component comprising a carrier (12) having a plurality of grooves (14) extending in an axial direction (A) and arranged distributed along a circumferential direction (U) of the carrier (12), wherein: - a plurality of hairpins (16) and at least one insulating element (18, 30, 36) are arranged at least partially in the groove (14), wherein: The hairpin (16) is electrically insulated relative to a groove wall defining a groove (14) of the carrier (12) by means of the at least one insulating element (18, 30, 36), and - The at least one insulating element (18, 30, 36) is supported on the groove wall of the carrier (12) via a wedge-shaped geometry (28), whereby a force acting on the wedge-shaped geometry (28) in the axial direction (A) is converted into a force acting in the circumferential direction (U), by means of which the insulating element (18, 30, 36) is pressed against the hairpin (18) in the circumferential direction (U).

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