Interphase insulation element and electric rotating machine

Abstract

Flexible interphase insulation element (60, 62, 64, 66) for isolating two adjacent phases of coil ends (50E, 52E) formed from a plurality of stator coils at an end surface (42a, 42b) of a stator core (40) in one direction of a rotating shaft (10), comprising: a flat section (601) that is arranged between the coil ends of two adjacent phases and isolates them from each other, a three-dimensional section (603) with a three-dimensional shape that protrudes from the flat section and guides a coil, a reinforcing element (4601, 5601) for the flat section (601) which is provided on both opposite surfaces of the flat section (601), and a reinforcing element (4603, 5603) for the three-dimensional section (603) which is provided on both opposite surfaces of the three-dimensional section (601), characterized in that the reinforcing element (4601, 5601) for the flat section (601) and the reinforcing element (4603, 5603) for the three-dimensional section (603) are configured to each include an epoxy material in contact with a bonding element comprising an epoxy resin, for securing a conductor forming the coil, and where epoxy resin layers (4601, 5603) of the reinforcing elements are in contact with each other at a connection surface between the flat section (601) and the three-dimensional section (603).

Description

Technical field

[0001] The present invention relates to an interphase insulating element and an electric rotating machine comprising this, and more precisely an interphase insulating element that isolates a plurality of coil ends from one another, and an electric rotating machine comprising this. Background of the invention

[0002] Conventional electric rotating machines are disclosed, for example, in Japanese patent publications number JP 2005 - 218 255 A (document 1) and JP 2005 - 20 942 A (document 2). Disclosure of the invention

[0003] Document 1, according to the prior art, discloses a reinforcement of an interphase insulation plate, wherein the section to be reinforced is made thicker or formed from a different material. According to this method, a thickness is increased to resist breakage, whereas a thickness is similarly increased to resist compression forming. Consequently, there is potential for improvement with regard to reducing motor size by compression forming of a stator core end surface.

[0004] In publication US 2005 / 0 168 097 A1, a phase isolation element according to the preamble of claim 1 is disclosed.

[0005] The publication JP 2004 - 289 952 A describes the construction of a fixing element for a coil end. Furthermore, the publication JP 2004 - 146 093 A describes the construction of an interphase insulating element.

[0006] The present invention has been made to overcome the difficulty described above, an associated objective being to provide an interphase isolation element that enables a reduction in the size of the electrical rotating machine.

[0007] This problem is solved by a flexible intermediate-phase insulation element according to claim 1. Advantageous embodiments are specified in the dependent claims.

[0008] Furthermore, an electric rotating machine according to claim 5 is provided.

[0009] According to one embodiment, a flexible interphase isolation element is provided for isolating two adjacent phases of coil ends formed by a plurality of stator coils at an end surface of a stator core in one direction of a rotating shaft, comprising: a flat section arranged between the coil ends of two adjacent phases and isolating them from each other, a three-dimensional section having a three-dimensional shape projecting from the flat section and guiding a coil, and a reinforcing element provided on a surface of the flat section.

[0010] The interphase insulation element, constructed as described above, can increase its strength against breakage while minimizing its strength against compression. This allows for a reduction in the size of the electrical rotating machine.

[0011] Preferably, the interphase insulation element further comprises a leg section connecting a plurality of flat sections, wherein the flat section and the leg section are formed from the same material. In this case, the leg section and the flat section are formed from the same material, thus reducing costs and improving productivity compared to a case where a reinforcement section made of a different material is formed on a surface of the section to be reinforced.

[0012] Preferably, the reinforcing element has a higher toughness than the flat section. Consequently, the strength against breakage is reliably improved, while the strength against compression forming is not increased more than necessary, which contributes to a reduction in the size of the electric rotary machine.

[0013] Preferably, the reinforcing element is a layer containing an epoxy material. The use of epoxy material improves the durability and dimensional stability properties of the interphase insulating element, thereby simplifying the assembly of the rotating electrical machine.

[0014] The interphase insulating element according to the present invention is a flexible interphase insulating element arranged between multiphase coil windings wound around a stator core and isolating them from each other, comprising a nonwoven fabric layer and an epoxy resin layer provided to be in contact with the nonwoven fabric layer.

[0015] In the interphase insulating element structure described above, the epoxy resin layer exhibits high toughness. Even when the interphase insulating element is bent, the epoxy resin layer applied to the surface stretches, preventing breakage of the element. As a result, its resistance to breakage is improved. Furthermore, because the epoxy resin layer is thin, an increase in the overall thickness of the interphase insulating element is prevented. Additionally, the epoxy resin layer bends easily, thus allowing for a reduction in the size of the electrical rotating machine that uses it.

[0016] The electrical rotating machine according to the present invention comprises the intermediate phase insulation element according to the invention as well as a binding element which is in contact with the epoxy resin layer and includes epoxy resin for securing the coil windings.

[0017] In the interphase insulation element structure described above, the binding element includes epoxy resin, whereby the binding element is consequently firmly connected to the interlayer insulation element, which allows for a tight winding and thus a reduced size of the electrical rotating machine.

[0018] According to the present invention, an intermediate phase insulation element can be provided which enables a reduction in the size of the electrical rotating machine and prevents breakage. Brief description of the drawing Fig. Figure 1 shows a schematic illustration of a cross-section comprising a rotating shaft of an electric rotating machine 100 according to an embodiment 1 of the present invention. Fig. Figure 2 shows a top view of the stator core, which is shown from the direction of arrow II according to Fig. 1 is considered. Fig. Figure 3 shows a perspective view of an interphase insulation element 60, 64 inserted between a coil end of a U-phase coil and a coil end of a V-phase coil. Fig. Figure 4 shows a perspective view of an interphase insulation element 62, 66 inserted between a coil end of a V-phase coil and a coil end of a W-phase coil. Fig. Figure 5 shows a perspective view illustrating an exemplary way in which this can be done. Fig. 3 shown intermediate phase insulation element 60 at one in Fig. 2 stator core 40 is attached. Fig. Figure 6 shows a top view accordingly Fig. 5, which is viewed from an end surface 42A of the stator core 40. Fig. 7 shows an example of one way in which a Fig. 4 Interphase insulation element 62 shown at the in Fig. 2 stator core 40 is attached. Fig. Figure 8 illustrates a process for producing the in Fig. 3 Interphase insulation element 60, 64 shown. Fig. Figure 9 illustrates a process for producing the in Fig. 3 Interphase insulation element 60, 64 shown. Fig. Figure 10 illustrates a process for producing the in Fig. 3 Interphase insulation element 60, 64 shown. Fig. Figure 11 illustrates a process for producing the in Fig. 3 Interphase insulation element shown 60,64. Fig. Figure 12 illustrates a process for producing the in Fig. 3 Interphase insulation element shown 60,64. Fig. Figure 13 shows a cross-sectional view extending along a line XIII-XIII in Fig. 12 is taken from. Fig. Figure 14 shows a cross-section of a flat section according to a further embodiment. Fig. Figure 15 shows a cross-section of a coil in contact with the flat section. Fig. Figure 16 shows a cross-section of a connecting section between the flat section and a nose section according to the present invention. Fig. Figure 17 shows a cross-section of a connecting section between the flat section and the nasal section according to a comparative example. Fig. Figure 18 shows a top view of a nonwoven fabric layer. Preferred embodiments of the invention

[0019] Exemplary embodiments of the present invention are described below with reference to the figures. In the exemplary embodiments described below, identical or corresponding sections are indicated by the same reference numerals, and a description thereof is not repeated.

[0020] In Fig. Figure 1 schematically shows a cross-section comprising a rotating shaft of an electric rotating machine 100 according to an embodiment of the present invention. With reference to Fig. The electrical rotating machine 100 comprises a rotor shaft 10, a rotor core 20, magnets 30 and 32, a stator core 40, coils 50 and 52, and interphase insulating elements 60 to 66. The coil 50 comprises a U-phase coil 51A, a V-phase coil 51B, and a W-phase coil 51C, and the coil 52 comprises a U-phase coil 53A, a V-phase coil 53B, and a W-phase coil 53C.

[0021] The rotor core 20 is formed by stacking and pressing together electromagnetic steel sheets with holes for receiving magnets 30 and 32, which form the rotor magnet poles at the outer circumferential sections. A rotor core 20 is mounted around a rotor shaft and rotates around the rotating shaft together with the rotating shaft 10. The magnets 30 and 32 are inserted into the aforementioned holes, which are formed at the outer circumferential sections of the rotor core 20, and form the rotor magnet poles.

[0022] The stator core 40 is formed by stacking and pressing together electromagnetic steel laminations in the direction of the rotating shaft. The stator core 40 is used in the

[0023] The outer circumference of the rotor core 20 is provided at a distance from the rotor core 20 and attached to a (not shown) housing of the electric rotating machine 100. The U-phase coils 51A and 53A, the V-phase coils 51B and 53B, and the W-phase coils 51C and 53C are each wound around the stator core 40 and form stator magnetic poles.

[0024] The interphase insulating element 60 is inserted between a coil end 50E of the U-phase coil 51A and a coil end 50E of the V-phase coil 51B at end surfaces 42A and 42B of the stator core 40 and insulates the V-phase coil 51B from the U-phase coil 51A. The interphase insulating element 62 is inserted between a coil end 50E of the V-phase coil 51B and a coil end 50E of the W-phase coil 51C and insulates the W-phase coil 51C from the V-phase coil 51B. Furthermore, the interphase insulating element 64 is inserted between a coil end 52E of the U-phase coil 53A and a coil end 52E of the V-phase coil 53B and insulates the V-phase coil 53B from the U-phase coil 53A. The interphase insulating element 66 is inserted between a coil end 52E of the V-phase coil 53B and a coil end 52E of the W-phase coil 53C and insulates the W-phase coil 53C from the V-phase coil 53B.

[0025] The U-phase coils 51A and 53A, the V-phase coils 51B and 53B, and the W-phase coils 51C and 53C are each wound around the stator core 40 and, after the interphase insulation elements 60 to 66 are inserted, are press-formed at the end surfaces 42A and 42B of the stator core 40 such that the coil ends 50E and 52E extend to the outer circumference of the stator core 40. When each of the coil ends 50E and 52E of the U-phase coils 51A and 53A, the V-phase coils 51B and 53B, and the W-phase coils 51C and 53C is press-formed, the interphase insulation elements 60 to 66 are deformed accordingly. However, each of the intermediate phase insulating elements 60 to 66 bends easily and exhibits high toughness, as described below, and consequently, even when the coil ends 50E and 52E are press-formed, the intermediate phase insulating elements 60 to 66 are free from plate deflection or damage.Thus, the electric rotating machine 100 can be made smaller due to the pressing of the coil ends 50E and 52E, while maintaining the insulation performance between all coils.

[0026] In Fig. 2 shows a top view of the stator core, taken from the direction of arrow II in Fig. 1 is considered. With reference to Fig. 2. Coils 511 to 518 form the U-phase coils 51A and 53A, coils 521 to 528 form the V-phase coils 51B and 53B, and coils 531 to 538 form W-phase coils 51C and 53C. Coils 511 to 518 are arranged at the outermost circumference, and coils 521 to 528 are arranged further inward than coils 511 to 518 and shifted by a prescribed position in the circumferential direction relative to coils 511 to 518. Furthermore, coils 531 to 538 are arranged further inward than coils 521 to 528 and shifted by a prescribed position in the circumferential direction relative to coils 521 to 528.

[0027] The interphase insulation elements 60 and 64 are inserted between coils 511 to 518 and coils 521 to 528. Fig. For the sake of simplicity, the interphase insulation elements 60 and 64 are shown continuously in the circumferential direction in Figure 2. In reality, the elements are divided into a plurality of interphase insulation elements, which include the interphase insulation elements 60 and 64. The interphase insulation elements 62 and 66 are inserted between the coils 521 to 528 and 531 to 538. For the sake of simplicity, the interphase insulation elements 62 and 66 are also shown continuously in the circumferential direction. In reality, however, the elements are divided into a plurality of interphase insulation elements, which include the interphase insulation elements 62 and 66.

[0028] Each of the coils 511 to 518, 521 to 528, and 531 to 538 is wound around a plurality of corresponding teeth. For example, coil 537 corresponds to teeth 2 to 6, being wound a prescribed number of times around teeth 2 to 6 as a whole. Other coils are likewise wound a prescribed number of times around the corresponding teeth as a whole in a similar manner to coil 537.

[0029] Coils 511 to 514 are connected in series, with one end being terminal U1 and the other end a neutral point UN1. Coils 515 to 518 are connected in series, with one end being terminal U2 and the other end a neutral point UN2. Coils 521 to 524 are connected in series, with one end being terminal V1 and the other end a neutral point VN1. Coils 525 to 528 are connected in series, with one end being terminal V2 and the other end a neutral point VN2. Coils 531 to 534 are connected in series, with one end being terminal W1 and the other end a neutral point WN1. Coils 535 to 538 are connected in series, with one end being terminal W2 and the other end a neutral point WN2.

[0030] In Fig. Figure 3 shows a perspective view of the interphase isolation element 60, 64, which is inserted between the coil end of the U-phase coil and the coil end of the V-phase coil. With reference to Fig. 3 comprise all intermediate phase insulation elements 60 and 64, flat sections 601 and 602, nasal sections 603 and 604, and leg sections 605 and 606. The flat sections 601 and 602 are cut out in sections corresponding to the nasal sections 603 and 604.

[0031] The nose sections 603 and 604 are formed from the same element as the flat sections 601 and 602, with the nose sections 603 and 604 each being attached to the corresponding cut-out sections of the flat sections 601 and 602. For example, the nose sections 603 and 604 are each firmly attached to the flat sections 601 and 602 by thermal compression bonding or adhesive tape. The nose sections 603 and 604 are positioned at the coil ends 50E and 52E to cover the portion of the coil that protrudes from the stator core 40 from the inner circumferential surface of the stator core 40.

[0032] Leg sections 605 and 606 are made of the same material as flat sections 601 and 602. Opposite ends of leg sections 605 and 606 are attached to flat sections 601 and 602 at their respective ends. Leg sections 605 and 606 are inserted into slots in the stator core 40. A distance H1 between flat sections 601 and 602, defined by leg sections 605 and 606, corresponds to the length of the stator core 40 in the direction of the rotating shaft.

[0033] In each interphase insulation element 60 and 64, leg sections 605 and 606 are inserted into the slot of the stator core 40, with the flat section 601 and the nose section 603 being inserted between the coil ends of the U-phase and V-phase coils on the end surface 42A of the stator core 40. Furthermore, the flat section 602 and the nose section 604 are inserted between the coil ends of the U-phase and V-phase coils on the end surface 42B of the stator core 40. In this process, each of the interphase insulation elements 60 and 64 is attached such that the nose sections 603 and 604 correspond to the sections where the U-phase coil stands out from the stator core 40, and that protruding sides of the nose sections 603 and 604 are opposite the inner circumferential side of the stator core 40.

[0034] In Fig. Figure 4 shows a perspective view of the interphase isolation element 62, 66, which is inserted between the coil end of the V-phase coil and the coil end of the W-phase coil. Each of the interphase isolation elements 62 and 66 comprises flat sections 621 and 622, nose sections 623 and 624, and leg sections 625 and 626. The basic structure of the interphase isolation element 62 and 66 is the same as that of the interphase isolation element 60 and 64, which is described in Figure 4. Fig. Figure 3 shows that each of the flat sections 621 and 622, the nose sections 623 and 624, and the leg sections 625 and 626 is formed by attaching a nonwoven fabric to opposite surfaces of a PET resin. The interphase insulation elements 62 and 66 differ from the interphase insulation elements 60 and 64 shown in Figure 3. Fig. Figure 3 shows the width of the nose section. Specifically, the width of the nose sections 623 and 624 of the intermediate phase insulating elements 62 and 66, which are arranged between the coil end of the V-phase coil and the coil end of the W-phase coil, is wider than the width of the nose sections 603 and 604 of the intermediate phase insulating elements 60 and 64, which are arranged between the coil end of the U-phase coil and the coil end of the V-phase coil. The reason for this is described below. When the coil end is pressed, the U-phase coil is formed first at the outermost circumference, with the V-phase and W-phase coils forming subsequently towards the inner circumferential side. Consequently, at the section where the coil emerges from the slot, the inner coil is deformed earlier in the circumferential direction.

[0035] The distance H2 between the flat sections 621 and 622, defined by the leg sections 625 and 626, is designed to be slightly longer than the distance H1 between the interphase insulation elements 60 and 64. This is because, at the end surfaces 42A and 42B of the stator core 40, the interphase insulation elements 62 and 66 are arranged on the upper layer side of the interphase insulation elements 60 and 64, with the V-phase coil positioned between them.

[0036] In Fig. Figure 5 shows a perspective view that illustrates how this is done in Fig. 3 Interphase insulation element 60 shown at the in Fig. 2 stator core 40 is attached, and in Fig. 6 is one of the Fig. Figure 5 shows a corresponding top view, viewed from the side of the end surface 42A of the stator core 40. Fig. 6 are enlarged sections around teeth 1 to 6 of the stator core 40 according to Fig. 2 shown, where the stator coil is not shown. Furthermore, although in the Fig. 5 and Fig. Figure 6 shows an intermediate phase insulation element 60 covering part of a coil end; in fact, a plurality of intermediate phase insulation elements 60 are provided close together in the circumferential direction of the stator core 40.

[0037] With reference to the Fig. 5 and Fig. The U-phase coils 511 and 518 (U-phase coil 511 is not shown) are each inserted into slots 16 and 15, respectively, extending from slots 16 and 15 and extending or being press-molded onto the outermost circumference of the end surface 42A of the stator core 40. The leg sections 605 and 606 of the interphase insulating element 60 are each inserted into slots 12 and 18, respectively, so that the nose section 603 is arranged corresponding to the slots 16 and 15 into which the U-phase coils 511 and 518 are inserted.

[0038] Subsequently, when the V-phase coils 527 and 528 (not shown), which are positioned further inward on the circumferential side than the intermediate phase insulation element 60, are extended or press-formed, the intermediate phase insulation element 60 is formed together with the V-phase coils 527 and 528 and compressed between the U-phase coils 511, 518 and the V-phase coils 527, 528 in the shape shown. The flat section 601 is folded or creased along line A of the nose section 603 to form an outwardly convex fold.

[0039] The coil end 50E of the U-phase coil 518 is approximately flat along the circumferential direction of the stator core 40, while it is distinctly three-dimensionally deformed at the exit section from the slot 15. Taking into account the shape of the coil exit section after such three-dimensional deformation, the nose sections 603 and 604 are provided on the interphase insulating element 60. Consequently, when the coil end 50E is press-formed, no plate deviation or damage occurs at the nose sections 603 and 604.

[0040] In the interphase insulating element 60, the nose sections 603 and 604, as well as the flat sections 601 and 602, are formed from separate elements, with the stiffness of the flat sections 601 and 602, which correspond to the sections where the coil end 50E is formed flat, not being significantly increased. This is because a higher stiffness of an interphase insulating layer is disadvantageous when preventing plate deviation. If the flat sections 601 and 602 have excessively high stiffness, the interphase insulating element would protrude considerably from the coil end 50E, hindering a reduction in the size of the rotating electric machine. Consequently, no significant plate deviation occurs in the flat sections 601 and 602 during pressing, and the flat sections 601 and 602 do not impede a reduction in the size of the rotating electric machine 100.

[0041] Furthermore, in the interphase insulation element 60, the leg sections 605 and 606, as well as the flat sections 601 and 602, are formed from separate elements, with the leg sections 605 and 606, which are inserted into the slots, being designed to be as thin as possible. Consequently, the leg sections 605 and 606 do not reduce the coil's occupancy ratio in the slot, thus ensuring that the performance of the rotating electric machine 100 is not impaired.

[0042] In Fig. 7 is an example of one way in which this is shown in Fig. 4 Interphase insulation element 62 shown at the in Fig. 2 shown stator core 40 is attached. Fig. Figure 7 shows an example where the intermediate phase insulation element 62 is installed after the intermediate phase insulation element 60 has been installed. Fig. Figure 7 also shows an interphase insulation element 62 covering part of a coil end. In fact, however, a multitude of interphase insulation elements 62 are provided densely in the circumferential direction of the stator core 40.

[0043] With reference to Fig. Figure 7 shows V-phase coils 527 and 528 (not shown) inserted into slots 13 and 14, respectively, extending from slots 13 and 14 towards the front of the figure and further towards the inner circumferential side than the U-phase coils 511 and 518 at the end surface 42A of the stator core 40, where they are press-molded. The intermediate phase insulation element 62 has leg sections 625 and 626, each inserted into slots 11 and 17, respectively, such that a nose section 623 is arranged corresponding to the slots 13 and 14 into which the V-phase coils 527 and 528 are inserted and corresponding to the nose section 603 of the intermediate phase insulation element 60.

[0044] Subsequently, if W-phase coils 536 and 537 (not shown), which are positioned further inward on the circumferential side than the intermediate-phase insulating element 62, extend / are press-molded, the intermediate-phase insulating element 62 is formed together with the W-phase coils 536 and 537 and compressed between the V-phase coils 527 and 528 and the W-phase coils 536 and 537. The flat section 621 is folded or inverted along a line B of the nose section 623 to form an outwardly convex fold.

[0045] The coil ends of the V-phase coils 527 and 528 are approximately flat along the circumferential direction of the stator core 40, while the sections emerging from slots 13 and 14 are distinctly three-dimensionally deformed. Considering the shape of the coil emergence section after such three-dimensional deformation, the nose sections 623 and 624 of the interphase insulating element 62 are similar to those of the interphase insulating element 60. Consequently, when the coil ends are press-formed, no plate deviation or damage occurs at the nose sections 623 and 624.

[0046] Furthermore, as described above, the V-phase coil is positioned further inward on its circumferential side after forming than the U-phase coil, and consequently, it is deformed earlier at the point where it emerges from the slot in the circumferential direction of the stator core 40 than the U-phase coil. Therefore, the V-phase coil extends over the nose section 603 of the interphase insulation element 60. Furthermore, the W-phase coil is positioned further inward on its circumferential side after forming than the V-phase coil, and consequently, it is deformed earlier at the point where it emerges from the slot in the circumferential direction of the stator core 40 than the V-phase coil.

[0047] In the interphase insulation element 62, taking into account the shape at the origin of the V-phase coil and the arrangement of the W-phase coil, the nose section 623 on the innermost circumference is provided wide enough to also cover the nose section 603 of the interphase insulation element 60. Consequently, the coil end of the W-phase coil can be reliably isolated from the coil end of the V-phase coil.

[0048] In the Fig. 8, Fig. 9, Fig. 10, Fig. 11 to Fig. 12 is a process for producing the in Fig. 3 illustrated by the intermediate phase insulation element 60, 64 shown. Fig. Figure 8 is a plan view of the flat sections 601 and 602 according to Fig. 3 shown during a manufacturing process. In Fig. Figure 9 is a top view of nose sections 603 and 604 according to Fig. 3 shown during a manufacturing process, and in Fig. Figure 10 shows a top view of leg sections 605 and 606 during manufacturing. Fig. 11 and Fig. Figure 12 shows first and second illustrations depicting the steps for manufacturing the interphase insulating element 60, which is formed by the flat sections 601 and 602, the nose sections 603 and 604, and the leg sections 605 and 606, which are located in the Fig. 8, Fig. 9 to Fig. 10 are shown, each being trained.

[0049] With reference to the Fig. 8, Fig. 9 to Fig. The flat sections 601 and 602 are formed by punching out a sheet of material 651. Each flat section 601 and 602 has a partially cut-out rectangular section. The flat sections 601 and 602 and the nose sections 603 and 604 can be formed by punching out a resin layer.

[0050] With reference to Fig. 11. After the flat sections 601 and 602 and the leg sections 605 and 606 have each been formed from the plate materials 651 and 653, opposite ends of the leg sections 605 and 606 are attached to the flat sections 601 and 602 at opposite ends of the flat sections 601 and 602. The flat sections 601 and 602 are arranged such that the respective cut-out sections are opposite each other with a distance H1 between them, this distance corresponding to the length of the stator core 40 in the direction of the rotating shaft. A plate for thermal compression bonding or an adhesive tape with sufficient adhesive strength is used for fastening.

[0051] With reference to Fig. 12. After leg sections 605 and 606 have been attached to flat sections 601 and 602, nose sections 603 and 604 are attached to the respective cut-out sections of flat sections 601 and 602. Similar to the attachment of leg sections 605 and 606 to sections 601 and 602, a thermal compression bandage plate or adhesive tape with sufficient adhesive strength is used for this purpose.

[0052] If the thickness of the leg sections 605 and 606 does not significantly reduce the coil occupancy ratio in the slot, the flat sections 601 and 602 and the leg sections 605 and 606 can be formed integrally. In this case, an unused area remains, surrounded by the flat sections 601 and 602 and the leg sections 605 and 606, and if the nose sections 603 and 604 are formed from this area, the production yield can be improved.

[0053] In the preceding description, leg sections 605 and 606 are attached to flat sections 601 and 602, and then nose sections 603 and 604 are attached to flat sections 601 and 602. The order of attaching leg sections 605 and 606 and nose sections 603 and 604 to flat sections 601 and 602 can be reversed. More precisely, nose sections 603 and 604 can be attached to flat sections 601 and 602 first, and then leg sections 605 and 606 can be attached to flat sections 601 and 602.

[0054] Although not shown in detail, the method for producing the interphase insulating elements 62 and 66, which are described in Fig. Figure 4 shows the same process for manufacturing the intermediate phase insulation elements 60 and 64 as described above.

[0055] In Fig. Figure 13 shows a cross-sectional view along a line XIII-XIII according to Fig. 12 is taken from. With reference to Fig. 13 The flat section 601 is formed from a nonwoven layer 1601, a polyethylene naphthalate (PEN) layer 601, and a nonwoven layer 3601, wherein an epoxy resin layer 4601 is provided on the nonwoven layer 3601. The thickness of the epoxy resin layer 4601 is thinner than that of the flat section 601. Furthermore, the epoxy resin layer 4601 has a higher toughness than the flat section 601 and exhibits sufficient deformability to resist breakage, even when stretched. Preferably, the epoxy resin layer 4601 is thinner than the nonwoven layer 3601. The nonwoven layers 1601 and 3601 are realized, for example, by NOMEX (registered trademark). Regarding the method for attaching the epoxy resin layer 4601 to the nonwoven fabric layer 3601, the preformed epoxy resin layer 4601 can be brought into contact with the nonwoven fabric layer 3601, and then the epoxy resin layer 4601 can be heated.Alternatively, the epoxy resin can be heated to make it flowable, and the semi-liquid epoxy resin can be applied to the surface of the nonwoven layer 3601 and cooled to form the epoxy resin layer 4601.

[0056] The highly tough epoxy resin layer 4601 serves to prevent breakage during folding and bending. Furthermore, the inner PEN layer 2601 is protected by the epoxy resin 4601, which prevents breakage.

[0057] In Fig. Figure 14 shows a cross-section of the flat section according to a further embodiment. With reference to Fig. 14. Epoxy resin layers 4601 and 5601 can be provided on both the front and rear surfaces of the flat section 601. The epoxy resin layers 4601 and 5601 are both formed thinner than the flat section 601. If the epoxy resin layers 4601 and 5601 are formed on both surfaces, the same formation process can be used as for forming the epoxy resin layer on only one surface, as described in Fig. As shown in section 13, they can be applied.

[0058] In Fig. Figure 15 shows a cross-sectional view of coils in contact with the flat section. With reference to Fig. In Figure 15, coils 518 and 528 are formed from conductors 1518 and 1528, respectively. To secure coils 518 and 528, conductors 1518 and 1528 are fixed by a resin material (a lacquer) 2518 containing epoxy resin. The conductor 1518, as the conducting element, is fixed by the lacquer 2518, the main component of which is the same as the epoxy resin forming the epoxy resin layers 4601 and 5601. Consequently, the lacquer 2518 adheres tightly to the epoxy resin layers 4601 and 5601, securely fixing the conductors 1518 and 1528, which form coils 1518 and 1528.

[0059] In Fig. Figure 16 shows a cross-section of a connecting section between the flat section and the nasal section. With reference to Fig. In section 16, both the flat section 601 and the nose section 603 exhibit a layered structure consisting of the epoxy resin layer 5601 (or 5603), the nonwoven fabric layer 1601 (or 1603), the PEN layer 2601 (or 2603), the nonwoven fabric layer 3601 (or 3603), and the epoxy resin layer 4601 (or 4603). At the interface between the flat section 601 and the nose section 603, the epoxy resin layers 4601 and 5603 are in contact with each other. Thus, strong adhesion between the epoxy resin layers is achieved.

[0060] In Fig. Figure 17 shows a cross-section of a connecting section between the flat section and the nose section according to a further embodiment. With reference to Fig. 17. This example differs from Fig. 16 in that the epoxy resin layer 5603 is not provided on the side of the nose section 603. As shown, the epoxy resin layer cannot be formed on one or both surfaces of the connection area. A configuration is preferred in which the epoxy resin layers are provided on both the nose section 603 and the flat section 601, and the epoxy resin layers are in contact with each other, as closer contact between them can be achieved.

[0061] In Fig. Figure 18 shows a top view of the nonwoven layer. With reference to Fig. 18 The nonwoven layer 1601 is an accumulation of fibers 2602, wherein the multitude of fibers 2602 is not interwoven. The fiber 2602 can be organic or inorganic and must have sufficient strength, as required by the flat section 601 and the nose section 603.

[0062] Specifically, the interphase insulating element according to the present invention is a flexible interphase insulating element 60, 62, 64, 66, which insulates two adjacent phases of coil ends 50E and 52E, which are connected by U-phase coils 51A and 53A, V-phase coils 51B and 53B and W-phase coils 51C and 53C as a plurality of stator coils at end surfaces 42a, 42b of a stator core 40 in the direction of a rotor shaft 10 as the rotating shaft, which comprises a flat section 601 arranged between adjacent coil ends of two phases and insulating them, and a nose section 603 as a three-dimensional section projecting from the flat section 601 and guiding the coil, and which has epoxy resin layers 4601 and 5601 as reinforcing elements applied to a surface of the flat section 601. are trained in section 601.The insulating element further comprises leg sections 605 and 606, which connect a plurality of the flat sections 601 and 602, wherein the flat sections 601 and 602 and the leg sections 605 and 606 are formed from the same material. The epoxy resin layers 4601 and 5601, acting as reinforcing elements, exhibit higher toughness than the flat sections 601 and 602. The intermediate-phase insulating element 60 comprises a nonwoven fabric layer 3601 and epoxy resin layers 4601 and 5601.

[0063] The interphase insulation elements 60, 62, 64 and 66 according to the present invention are flexible interphase insulation elements arranged between the U-phase coils 51A and 53A, the V-phase coils 51B and 53B and the W-phase coils 51C and 53C as multiphase coil windings wound around the stator core, and insulating them from each other, wherein the insulation element comprises nonwoven fabric layers 1603 and 3603 and the epoxy resin layers 4603 and 5603, which are provided to be in contact with the nonwoven fabric layers 1603 and 3603.

[0064] The electric rotating machine according to the present invention comprises the intermediate phase insulation elements 60, 62, 64 and 66 as well as a varnish 2518 as a binding element, which includes epoxy resin, for securing the coil windings.

[0065] The intermediate phase insulation elements 60, 62, 64, and 66, constructed as described above, are coated with epoxy resin layers 4601 and 5601, thus preventing breakage even when the intermediate phase insulation elements 60, 62, 64, and 66 are pulled. Furthermore, even when each coil is pressed against the intermediate phase insulation element 60, breakage of the intermediate phase insulation element 60, 62, 64, and 66 is prevented because the intermediate phase insulation element 60, 62, 64, and 66 exhibits high toughness. Additionally, the epoxy resin layers 4601 and 5601 are flexible and therefore do not impede deformation of the intermediate phase insulation element 60, 62, 64, and 66. As a result, the size of the rotating electrical machine is not increased.

[0066] The embodiments described here are purely illustrative and should not be interpreted as limiting the scope of the invention. The scope of the present invention is defined by the claims, taking into appropriate consideration the description of the embodiments, and includes modifications within the meaning of the claim wording and related equivalents.

Claims

[1] Flexible interphase insulation element (60, 62, 64, 66) for isolating two adjacent phases of coil ends (50E, 52E) formed from a plurality of stator coils at an end surface (42a, 42b) of a stator core (40) in one direction of a rotating shaft (10), comprising: a flat section (601) that is arranged between the coil ends of two adjacent phases and isolates them from each other, a three-dimensional section (603) with a three-dimensional shape that protrudes from the flat section and guides a coil, a reinforcing element (4601, 5601) for the flat section (601) which is provided on both opposite surfaces of the flat section (601), and a reinforcing element (4603, 5603) for the three-dimensional section (603) which is provided on both opposite surfaces of the three-dimensional section (601), characterized by, that the reinforcing element (4601, 5601) for the flat section (601) and the reinforcing element (4603, 5603) for the three-dimensional section (603) are each configured to include an epoxy material in contact with a bonding element which includes an epoxy resin, to secure a conductor which forms the coil, and where epoxy resin layers (4601, 5603) of the reinforcing elements are in contact with each other at a connection surface between the flat section (601) and the three-dimensional section (603). [2] Interphase isolation element according to claim 1, further comprising: a leg section (605, 606) that connects a plurality of the flat sections, wherein the flat section and the leg section are formed from the same material. [3] Interphase insulation element according to claim 1, wherein the reinforcing element has a higher toughness than the flat section. [4] Interphase insulation element according to one of claims 1 to 3, wherein the flexible interphase insulation element (60, 62, 64, 66) comprises a nonwoven layer (1603, 3603). [5] Electric rotating machine with: the interphase insulation element (60, 62, 64, 66) according to one of claims 1 to 4, and a binding element (2518) that is in contact with the epoxy material and contains an epoxy resin, for securing windings that form the coil.

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