Coil module for electric machines

Abstract

To provide a coil module for an electric machine capable of realizing a thin structure with a small space requirement. A coil module 18 for an electric machine includes first and second coil carriers 15, 15a, 15b made of an electrically insulating material, at least one winding portion 13 made of an electrically conductive material embedded in the first and second coil carriers 15, 15a, 15b, and first and second coil disks 6, 6a, 6b having first and second ceramic interfaces 56, 56a, 56b. The first and second coil disks 6, 6a, 6b are configured and attached to each other such that a substantially annular cooling passage 23 for a coolant is formed between the first and second coil disks 6, 6a, 6b. The first and second ceramic interfaces 56, 56a, 56b at least partially form the inner walls of the substantially annular cooling passage 23, respectively.

Description

[Technical field]

[0001] The invention relates to a coil module for an electric machine and / or an electric appliance and / or a vehicle and / or a machine tool. [Background technology]

[0002] Various designs of electric machines are known from the prior art: DE 10 2017 204 072 A1 describes a type of meandering winding for electric motors, which ensures a high density of conductive material entering the magnetic field region generated by the permanent magnets. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] DE 102017204072 Summary of the Invention [Problem to be solved by the invention]

[0004] Although rectangular wires have been used, their electromagnetic properties are unfavourable for such constructions, leading to inefficiencies, and multi-phase designs are difficult.

[0005] The present invention is therefore based on the problem of proposing a coil module for an electric machine, which makes it possible to overcome these disadvantages and to realize a thin construction with low space requirements. A further problem is based on the present invention to cool the electric machine reliably and / or effectively and / or space-savingly and / or lightly and / or to increase its service life. [Means for solving the problem]

[0006] In the context of the present invention, "electric machine" should be understood to refer to any device that converts electrical energy into mechanical work, or vice versa. In particular, the term "electric machine" should be understood to mean any power machine, electric motor, electric motor, generator, or generator.

[0007] According to the present invention, one or more or all of the above-mentioned problems are solved by a coil module and / or an electric machine and / or a vehicle or a machine tool as described below.

[0008] A coil module for an electric machine comprises at least one coil disk. Each coil disk has a coil carrier made of an electrically insulating material and a number of respective windings made of an electrically conductive material, typically in the form of windings. The windings are embedded, e.g. molded, in the coil carrier. The windings are arranged on the at least one coil disk in a circumferential direction around a center of the at least one coil disk. The windings each have two active regions extending radially from the center and two passive regions extending tangentially at radially outer and inner edges. In a plan view of the at least one coil disk, the active regions of different windings do not overlap each other, whereas each passive region of any one of the windings overlaps the corresponding passive regions of two immediately adjacent windings. The axial cross-sectional thickness of each of the windings is greater in the active region than in the passive region of the respective winding.

[0009] Although the term "plurality of winding sections" is used in this specification, there are cases where a plurality of electrical winding sections (for example, winding sections of the same phase) are connected to each other.

[0010] An "active region" is to be understood as a region of a winding that is suitable to contribute to the torque of the electric machine and / or that will be located in the magnetic field of at least one adjacent magnet module of the electric machine, whereas a "passive region" of a winding is a region that is not suitable to contribute to the torque of the electric machine and / or that will not be located in the magnetic field of an adjacent magnet module of the electric machine.

[0011] In the context of this specification, the expressions "the axial thickness ... of each winding" and "axial thickness" of a winding should be understood to refer to the thickness of the winding, measured in the axial direction. Similarly, the expression "tangential or radial width" of a winding should be understood to refer to the width of the winding, measured in the tangential or radial direction. That is, the specifications "axial", "tangential", "radial", etc. refer to the direction of measurement of the respective value (e.g. thickness, width, etc.).

[0012] Due to the partial overlap of the passive areas, the amount of conductive material (preferably copper, etc.) in the passive areas is generally twice that in the active areas. In order to prevent the axial thickness of the coil disk or the coil module formed of at least one coil disk from becoming too thick, the axial thickness of the cross section is made thicker in the active areas than in the passive areas. This ensures a thin structure. Here, "electrically insulating material" refers to a material that has a thermal conductivity of 10 -8 It is to be understood that a material with a conductivity of less than 10 S / m at a temperature of 25° C. is a material with a conductivity of less than 10 S / m at a temperature of 25° C. 6It should be understood that the term "radial direction" in this specification refers to any material having a linear coefficient of thermal conductivity exceeding 1 / 2 S / m. In this specification, "radial direction" should be understood to mean, according to common convention, a linear direction from the center to the edge. Also, "tangential direction" should be understood to mean a direction perpendicular to the radial direction. In the context of this specification, "passive area" should be understood to mean a region of a winding that does not extend radially but connects two active areas of the same winding. However, the passive area does not have to extend strictly in the tangential direction. For example, it is also preferable if the passive area includes a short radially extending region adjacent to the active area, which also changes, for example, in cross section. By changing the cross section between the active area and the passive area for each winding arranged in the circumferential direction, the axial distance of the gap between the magnet disks can be changed. This makes it possible to relatively increase the copper filling factor. In addition, the thickness of the passive area is reduced, making it easier to accommodate a three-phase arrangement configuration of the winding. In the context of this specification, the term "top view" is to be understood as a view / perspective along the normal vector of at least one coil disc. On the other hand, the term "side view" is to be understood as a view / perspective along the normal vector of at least one coil disc, tilted by 90°. The term "normal vector" is to be understood as a vector originating from a face of at least one coil disc, the length and width of which are greater than the thickness. Thus, in an electric machine, the normal vector is parallel to the axis of rotation. The windings, also called coils, are preferably in the form of coreless windings, i.e. metal coreless windings. In the context of this specification, the term "coil carrier" is to be understood as specifically a carrier of the windings (i.e. the coil). The coil carrier is typically a mechanical joint between the windings, and is preferably made of epoxy resin or other types of heat-resistant plastic. In the context of this specification, the term "coil disc" is to be understood as a corresponding annular body, to which the coil (i.e. the windings) are fixed by the coil carrier. On the other hand, the term "coil module" refers to a unitary body completely containing at least one coil disk, typically two or more coil disks.

[0013] For example, each of the plurality of windings may be molded into the material of the coil carrier (preferably an epoxy resin) to form the coil disc.

[0014] In each of the windings, the ratio of the thickness of the passive area to the thickness of the active area may be less than 1. Preferably, the ratio is greater than or equal to 0.3 and less than 1. For the outer passive areas, taking advantage of the ample installation space, it is highly preferred to set the ratio to just 0.5 so that the passive areas have a uniform relative thickness (=1) with respect to the active area when viewed from the coil disk.

[0015] Typically, at the transition from active to passive area, the shape of the cross-sectional area of ​​each winding section changes. Preferably, the area of ​​this cross-sectional area remains the same while maximizing the packing factor. This can be done, for example, by pressing. The change in shape allows the magnetic field lines to pass through more material, making the drive more efficient. The change in shape allows the spacing between magnets to remain the same, creating more space for conductive material within the electric machine, with corresponding improvements in performance and efficiency.

[0016] The active areas of the different winding sections (typically all of the winding sections) may entirely lie in and / or intersect the same plane in a side view.

[0017] This plane may be perpendicular to the axial direction of the coil disk or the electric machine. Also, the upper and / or lower surfaces of the active area may not be parallel to the plane, given that the thickness of the active area may vary (e.g., in embodiments in which the active area diverges). Preferably, the active area is configured to intersect with the plane, but may not include one or more active areas on which webs or the like described herein are constructed.

[0018] That is, the active areas of the separate winding portions may all be located at the same height in a side view along the normal vector of the coil disk, such that no active area protrudes from the other active areas, and may not include, for example, one or more active areas on which webs or the like described herein are constructed.

[0019] A coplanar arrangement results in all active areas being equally located in the magnetic field of any magnet module. Alternatively, it is also preferred that the active areas of substantially all separate windings (preferably all but one of the windings) are all located at the same height in a side view along the normal vector of the coil disk, e.g. only a few active areas (preferably one active area) protrude from the other active areas. This area may be provided with, for example, webs as described herein.

[0020] Preferably, the axial thickness of the active area of ​​each of the windings decreases in a radially outward direction and the tangential width of the active area of ​​each of the windings increases in a radially outward direction.

[0021] In other words, each active area flares outward.

[0022] This diverging active area configuration allows for more conductive material to be used in each winding without changing the axial thickness of the coil disk, thereby increasing the power and / or efficiency of the electric machine.

[0023] However, the divergent configuration does not have to be present throughout the active region of the winding, for example, each active region on a passive region side may have a transition portion that is excluded from this divergent configuration.

[0024] Preferably, the cross-sectional area of ​​the active region is constant along the radial direction.

[0025] Generally, the winding portion is made of a thin strand of multiple wires that are electrically insulated from each other and have a wire diameter of 0.1 mm or less. By providing multiple strands with an insulating coating, it is possible to ensure sufficient flexibility of the winding portion made of the wire during manufacturing and to achieve sufficiently high electrical conductivity.

[0026] Preferably, the number of windings corresponds to an integer multiple of three to allow a three-phase operation. That is, the windings form a total of three rows of different phases. In a highly preferred manner, the active areas of the windings of all phases are entirely in the same plane in side view, whereas the passive areas of each phase are distributed in two planes. Typically, the passive areas of two phases are in the same plane, whereas the passive area of ​​the third phase is displaced to another plane. Typically, the two planes are separate (i.e. offset) from each other, but parallel to each other.

[0027] All of the windings may be of the same construction, i.e., in particular, of the same size and shape. Alternatively, one or more of the windings used may have a different shape or thickness than the other windings.

[0028] The coil disk may be configured such that the axial thickness of the inner passive area and the outer passive area is different in any of the windings. Here, the "inner passive area" refers to a passive area located closer to the center of the coil disk or the coil module than the "outer passive area". In general, the thickness of the outer passive area in any of the windings is selected such that the ratio of the thickness of the outer passive area to the thickness of the active area is 0.5 or less. The inner passive area may be set such that the ratio of the thickness of the inner passive area to the thickness of the active area is less than 1. This allows the cooling surface to be further expanded from the active area to the outer passive area.

[0029] The invention further relates to an electric machine comprising a bearing structure and a shaft guided by said bearing structure, along which are arranged coaxially at least one magnet module consisting of a plurality of permanent magnets and at least one coil module as disclosed within the scope of this specification.

[0030] The electric machine, such as an electric motor, electric motor, generator or electrical generator, comprises a bearing arrangement and a shaft guided by the bearing arrangement, along which at least one magnet module consisting of a plurality of permanent magnets and at least one coil module of the nature described above are arranged coaxially, the magnet module being attached to the shaft and the coil module being connected to a housing. The high packing density of the windings results in highly advantageous efficiency and power density during operation of the electric machine.

[0031] The at least one coil module may be covered with a membrane of an electrically insulating material at least on the side facing the magnet module, in order to prevent liquid penetration and to allow the formation of cooling channels, which membrane can be applied by other joining methods besides adhesive bonding, such as welding as a material-material joint or friction-fit joint, e.g. screwing via a ring.

[0032] The at least one coil module may have at least two interconnected coil disks and a cooling channel formed in the space between the two coil disks for efficient cooling of the electric machine, in particular the active area. Alternatively or additionally, the cooling channel may be formed and bounded by the coil disk or coil module and the membrane body.

[0033] The invention further relates to a vehicle, machine or tool equipped with an electric machine as disclosed within the present specification.

[0034] One or more or all of the problems underlying the present invention are solved by the invention of a coil module and / or an electric machine and / or a vehicle and / or a machine tool disclosed hereinafter.

[0035] The coil modules described below include some of the configurations disclosed in relation to the coil modules described above, and therefore the technical effects, advantages, and descriptions described above also apply to the corresponding configurations described below, and more specifically, the coil modules described below may preferably include any of the configurations described in relation to the coil modules described above.

[0036] The coil module comprises a first coil disk having at least one winding made of a conductive material and a second coil disk having at least one winding made of a conductive material, the first coil disk and / or the second coil disk having a generally annular recess, the first coil disk and the second coil disk further being attached to one another such that the generally annular recess defines a generally annular cooling passage for a coolant between the first coil disk and the second coil disk.

[0037] The coil module, the first coil disc, the second coil disc, and the windings of the first and second coil discs may be configured as previously disclosed.

[0038] "Substantially annular recess" is to be understood to mean a recess that extends substantially around the entire circumference of the coil disc. The term "substantially" means, for example, that the substantially annular recess includes one (or more) webs, as will be described in more detail below, that interrupt the substantially annular recess. The substantially annular recess may extend around a centre of the coil disc, but may not be at the centre of the coil disc. "Centre of coil disc" is to be understood to mean a point on the coil disc through which the axis of rotation of the shaft or electric machine passes.

[0039] The radially outer and / or radially inner edges of the generally annular recess may be circular in plan view of the coil disc (i.e., perpendicular to the length and width directions). Here, the "radially outer edge" and "radially inner edge" of the recess refer to the transition from the generally flat surface of the coil disc to the generally annular recess, respectively. However, the shape of the outer and / or inner edges may deviate from a perfect circle. For example, the outer and / or inner edges may be wavy. Also, the outer and / or inner edges may be polygonal.

[0040] The cross section of the recess may be a rectangular cross section having two side surfaces and a bottom surface. Alternatively, the cross section of the recess may be a trapezoidal cross section in which the distance between the side surfaces decreases toward the bottom surface. Alternatively, the cross section of the recess may be an arc or curved cross section.

[0041] In other words, the annular recess is to be understood as a substantially annular depression in the coil disc, the thickness of which may be less in the region of the substantially annular recess than in the region outside the annular recess.

[0042] Preferably, the coil disk is manufactured by molding the at least one winding portion in the electrically insulating material (e.g., epoxy resin, etc.). For this purpose, the winding portion is placed in a mold, which may then be filled with the electrically insulating material. The substantially annular recess may then be formed by a press molding process. For example, a substantially annular mold, punch, etc. may be used.

[0043] The die into which the at least one winding is placed may have a protrusion that maintains a gap between the active areas of the windings. The coil disk may then have a gap between the active areas of the windings in the generally annular region in which the active areas are located. A coil disk with such a gap may be very suitable for air cooling the electric machine. However, other forms of cooling, for example using a coolant (such as a water-glycol mixture), may also be suitable.

[0044] For active areas of the flared configuration described herein, the protrusions in the mold may be preferably omitted, so that after molding, the distance between the active areas can be very close and no gaps remain between the active areas.

[0045] However, the generally annular recess can also be formed in a different way, for example by forming the recess in the mold itself, into which the electrically insulating material is poured, thereby making a subsequent press-molding process unnecessary, or by forming the generally annular recess, for example by milling.

[0046] Such a generally annular recess may be provided in one of the first and / or second coil discs. Preferably, each of the first and second coil discs is provided with a generally annular recess.

[0047] As already mentioned, in the context of this specification a "disk" is to be understood as an object whose length and width (i.e. diameter) are much larger than their thickness (e.g. ten times larger). A "side" of the disk is to be understood as a side of the object parallel to the plane in which its length and width extend, i.e. perpendicular to the axial direction of the electric machine. The substantially annular recess is provided in one such side of the coil disk. However, the coil disk may have a substantially annular recess in each of two such sides.

[0048] The first coil disk and the second coil disk may be attached to each other such that one of the two side surfaces of the first coil disk contacts one of the two side surfaces of the second coil disk, without excluding a configuration in which a sealing layer is provided between them. For example, the first coil disk and the second coil disk may be glued to each other, and at the same time, the adhesive may seal, for example, the cooling channels from the outside.

[0049] Hereinafter, among the side surfaces of the first coil disk and the second coil disk, the side surface that contacts the other coil disk will be referred to as the "inner side surface." Correspondingly, among the side surfaces of the first and second coil disks, the side surface that faces outward and does not contact the other coil disk will be referred to as the "outer side surface." In other words, it should be understood that the substantially annular recess is provided on the inner side surface of the first coil disk and / or the inner side surface of the second coil disk.

[0050] If the first and second coil disks each have a recess, the recesses of the first and second coil disks preferably have the same shape and are preferably arranged completely opposite and / or exactly overlapping each other, however, it is also possible that the shape of the recess of the first coil disk is different from the shape of the recess of the second coil disk and / or that they are misaligned with each other after assembly of the coil module.

[0051] A "substantially annular cooling channel" may refer to a space bounded by the first and second coil disks, bounded by the walls of the recesses of the first or second coil disk and the inner surface of the second coil disk. Preferably, the substantially annular cooling channel is bounded by two recesses in the first and second coil disks. However, the substantially annular cooling channel does not have to be completely enclosed. That is, the substantially annular cooling channel may comprise, for example, inlet and / or outlet openings through which a coolant may enter and / or exit the cooling channel.

[0052] This cooling channel has the advantage that the coolant can be brought very close to the windings, which allows the electric machine to be cooled very effectively. At the same time, this cooling structure saves space and weight, since no additional components are required to guide the coolant. Moreover, this cooling structure is very robust and unlikely to fail.

[0053] The refrigerant is preferably a water-based refrigerant, more preferably a water-glycol mixture, however, transformer oil can also be used as the refrigerant, although the coil modules described herein may be air-cooled.

[0054] Preferably, the first coil disk and / or the second coil disk have inlet openings in the recessed portion for directing coolant into the generally annular cooling channel, alternatively or additionally, the first coil disk and / or the second coil disk have outlet openings in the recessed portion for directing coolant out of the generally annular cooling channel.

[0055] For example, the inlet opening and / or the outlet opening may be provided on a radially outer side of the recess. Preferably, the inlet opening is provided on a side of the recess of the first coil disc and the outlet opening is provided on a side of the second recess, or vice versa. An inlet flow passage may extend from the inlet opening of the first coil disc, and an outlet flow passage may extend from the outlet opening of the second coil disc. These inlet flow passages and outlet flow passages may extend radially outward from the inlet opening and the outlet opening, respectively. The inlet flow passage may be configured as a recess in the first coil disc, and the outlet flow passage may be configured as a recess in the second coil disc. At the end of the inlet flow passage opposite to the inlet opening, there may be an inlet hole and / or an inlet through hole provided in the first coil disc and the second coil disc to guide the coolant into the inlet flow passage. At the end of the outlet flow path opposite the outflow opening, there may be an outflow hole and / or an outflow through hole provided in the first coil disk and the second coil disk so as to guide the refrigerant out of the outlet flow path.

[0056] Preferably, the inlet and / or outlet channels extend into outer passive areas of the immediately adjacent windings of a given winding which do not cover or only partially cover the outer passive areas of the windings, such that the inlet and / or outlet channels are located in areas of maximum thinness of the windings, which allows for a space-saving arrangement.

[0057] Alternatively, the inlet and outlet openings and the inlet and outlet channels may be provided in only one of the two coil discs or in both coil discs.

[0058] When the electric machine is formed by connecting a plurality of coil modules to each other via coil spacers, the coil spacers may also have inlet and outlet holes. In an assembled state, the inlet holes of each coil module overlap with the inlet holes of the coil spacers arranged therebetween. Similarly, in an assembled state, the outlet holes of each coil module overlap with the outlet holes of the coil spacers arranged therebetween. In other words, all the inlet and outlet holes may be aligned on the same line.

[0059] For example, the inlet and outlet holes may be omitted for the coil disk or coil spacer located at one end of the electric machine in the axial direction. The coolant can be supplied to each coil module through the inlet and outlet holes of the coil disk or coil spacer located at the other end of the electric machine. This allows the coil modules to be connected in parallel based on the flow of the coolant.

[0060] The first connecting line connecting the inlet opening and the center of the coil disk and the second connecting line connecting the outlet opening and the center of the coil disk may preferably have an angle of less than 30°, more preferably less than 20°, and even more preferably less than 10° in a plan view of the coil disk. Specifically, it is preferable to arrange these openings as close to each other as possible so that the corresponding angle is as small as possible. This ensures that the coolant flows around the entire center of the coil disk to the maximum extent possible, thereby ensuring that all the windings are cooled.

[0061] Preferably, the first coil disk and / or the second coil disk have a web in the recess between the inlet and outlet openings, the web being arranged to partition the substantially annular cooling passage between the inlet and outlet openings, it being understood that the web is arranged at the shortest connection of the inlet and outlet openings in the recess, allowing the coolant to flow around substantially the entire circumference of the coil disk.

[0062] The web can be interpreted as a discontinuity in the recess. That is, the web should be understood to extend from the radially inner edge of the recess to the radially outer edge of the recess. For example, the web may extend radially from the inner edge of the recess to the outer edge of the recess. Alternatively, the web may be angled with respect to the radial direction. In this case, the top surface of the web may be located above the bottom surface of the recess, and is preferably located on the same plane as the remaining inner surface of the coil disk. In this case, it is preferable that the web is configured as narrow as possible while still effectively blocking the refrigerant.

[0063] Also, preferably, the first connecting line connecting the inlet opening to the coil disc center and the second connecting line connecting the outlet opening to the coil disc center subtend an angle of less than 30°.The web between the inlet and outlet openings prevents the coolant from following the "short path" between the inlet and outlet openings, but forces the coolant to flow through the remaining, much larger, arcuate portion of the cooling channel.

[0064] The web forms a blockage for the coolant within the cooling channel, such that the web allows the coolant to flow to all target areas of the first and second coil disks, thereby ensuring that all target areas of the first and second coil disks are cooled.

[0065] Preferably, the first coil disc and the second coil disc each have a recess and a web, and in the assembled state of the coil module, the web of the first coil disc and the web of the second coil disc overlap each other, although this does not exclude a configuration in which an adhesive and / or sealing layer is provided between them, which adhesive can also provide a seal at the same time.

[0066] Preferably, the first coil disk and the second coil disk each include at least one coil carrier made of an electrically insulating material and a plurality of windings made of an electrically conductive material, the plurality of windings being arranged on the at least one coil disk in a circumferential direction around a center of the at least one coil disk. Each of the windings has two active regions extending radially from the center and two passive regions extending tangentially at radially outer and inner edges. In a plan view of the coil disk, the active regions of different windings do not overlap each other, whereas each passive region of any one of the windings partially overlaps the corresponding passive regions of two immediately adjacent windings. The axial thickness of the cross section of each of the windings is greater in the active regions than in the passive regions.

[0067] Further technical effects and / or advantages and / or explanations of the above configurations have been disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0068] Preferably, the recess is located at least in the region of the radially extending active area, and preferably also in the region of the radially outer passive area.

[0069] Since the passive areas of any of the windings overlap the corresponding passive areas of the immediately adjacent windings, whereas the active areas of the different windings do not overlap each other, a space for the recesses can be provided in the active areas of the first and / or second coil disks, which can be used for cooling purposes by using the recesses as the cooling channels, without wasting additional space. At the same time, this type of winding offers the advantage that more conductive material can be used in a small space.

[0070] However, the recess may be at least partially provided in the passive area, preferably in the radially outer passive area. For example, the radial width of the radially outer passive area may be greater than the radial width of the radially inner passive area. This allows the axial thickness of the radially outer passive area to be made thin. It is also possible that the passive area of ​​each winding part is not entirely covered by the passive area of ​​the directly adjacent winding part. This allows, for example, a space for the recess to be provided in the passive area as well.

[0071] Preferably, an axial thickness of the active area of ​​each winding portion of the first and / or second coil disk decreases in a radially outward direction and a tangential width of the active area of ​​each winding portion of the first and / or second coil disk increases in a radially outward direction.

[0072] This structure is also referred to as a "flared" configuration of the active area.

[0073] Here, the "axial thickness" does not have to decrease outwardly along the entire length of the active area, and the "tangential width" does not have to increase outwardly along the entire length of the active area, but it is preferred that the active area diverges along at least 70% of its length, preferably at least 90%.

[0074] Further technical effects and / or advantages and / or explanations of the above configurations have been disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0075] Another advantage of the flared configuration is that it allows for a small distance or gap between the active area of ​​any winding section and the active area of ​​any immediately adjacent winding section.

[0076] The advantage obtained is that, when the recess is located in the active area of ​​the winding, the bottom of the recess is sealed by the coil disc itself, which means that there are no gaps between the active areas of the winding and no additional sealing is required, i.e. the coil disc is not only self-contained but also self-sealing.

[0077] This allows, for example, to omit the membrane already mentioned and reduce the overall axial thickness of the coil module, which allows the magnet modules of the electric machine to be closer to the windings, thus increasing the performance and / or efficiency of the electric machine.

[0078] This also means that fewer method steps are required to manufacture the coil disc and / or coil module and / or the electric machine. Furthermore, the tooling for forming the coil disc can be simplified since it is not necessary to maintain a gap between the active areas of the windings. Overall, this reduces the manufacturing costs of the electric machine.

[0079] Preferably, the distance between the active area of ​​any winding section and the active area of ​​a directly adjacent winding section is a few micrometers.

[0080] Preferably, the axial depth of said recess increases radially outwardly.

[0081] The axial depth of the recess should be understood to mean the depth of the recess measured in the axial direction, e.g., the difference between the lowest point of the recess (e.g., the bottom surface, etc.) and the plane formed by the inner surface of the coil disc.

[0082] The configuration in which the axial depth of the recess increases radially outward should be understood to mean that the depth of a radially inner, approximately annular region of the recess is shallower than the depth of a radially outer, approximately annular region of the recess.

[0083] The depth may increase continuously (i.e., without interruption) or stepwise (i.e., discontinuously) from the inside to the outside, and the depth may increase linearly or non-linearly from the inside to the outside.

[0084] Such a geometry of the recess is also referred to as a "V-cooling" geometry.

[0085] Preferably, in each of the windings, the ratio of the thickness of the passive area to the thickness of the active area is less than one.

[0086] The technical effects and / or advantages and / or explanations of the above configurations have been previously disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0087] Preferably, in each of the winding portions, a ratio of a thickness of the passive region to a thickness of the active region is equal to or greater than 0.3 and less than 1.

[0088] The technical effects and / or advantages and / or explanations of the above configurations have been previously disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0089] Preferably, the sum of the axial thicknesses of the overlapping passive areas of two directly adjacent winding parts is greater than the axial thickness of the active areas of each of these two directly adjacent winding parts. For example, the sum of the axial thicknesses of the overlapping inner passive areas of two directly adjacent winding parts and the sum of the axial thicknesses of the overlapping outer passive areas of two directly adjacent winding parts is greater than the axial thickness of the active areas of each of these two directly adjacent winding parts. In a variant, the sum of the axial thicknesses of the overlapping inner passive areas of two directly adjacent winding parts can be greater than the axial thickness of the active areas of each of these two directly adjacent winding parts, whereas the sum of the axial thicknesses of the overlapping outer passive areas of two directly adjacent winding parts can be less than the axial thickness of the active areas of each of these two directly adjacent winding parts.

[0090] To achieve a smooth transition in thickness, each short section of the winding may have a thickness different from the thicknesses mentioned above.

[0091] This may apply to all or nearly all immediately adjacent windings, i.e., one or more active areas may be located in the regions of the web described herein, and in that case, the thickness of the active area may be greater than the thickness of the other active areas.

[0092] The "sum of the axial thicknesses of the overlapping passive areas of two directly adjacent winding sections" should be understood to mean the sum of the axial thicknesses of each passive area of ​​each winding section measured in the overlapping area of ​​the passive areas of these directly adjacent winding sections.

[0093] This can apply to both the radially inner passive area and the radially outer passive area. Alternatively, only the sum of the axial thicknesses of the radially inner passive areas of two immediately adjacent winding sections may be set to be greater than the axial thickness of the active area of ​​each of these two immediately adjacent winding sections.

[0094] This advantageously results in the active area and optionally the outer passive area collectively taking up less axial space than the passive area, so that space for the recess of the coil disc is reserved in the active area and optionally the outer passive area.

[0095] Preferably, the ratio of the sum of the axial thicknesses of the overlapping passive areas of two immediately adjacent winding sections to the maximum axial thickness of the active areas of each of these two immediately adjacent winding sections exceeds 1.

[0096] This can be applied to all immediately adjacent winding sections.

[0097] Preferably, at the transition from the active region to the passive region, the shape of the cross-sectional area of ​​each said winding changes.

[0098] The technical effects and / or advantages and / or explanations of the above configurations have been previously disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0099] Preferably, the active areas of the separate winding portions are entirely located in the same plane in a side view.

[0100] The technical effects and / or advantages and / or explanations of the above configurations have been previously disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0101] Preferably, the winding portion is made of a thin strand of a plurality of wires, each wire having a diameter of 0.1 mm or less, that are electrically insulated from one another.

[0102] The technical effects and / or advantages and / or explanations of the above configurations have been previously disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0103] Preferably, the number of windings corresponds to an integer multiple of three to allow three-phase operation.

[0104] The technical effects and / or advantages and / or explanations of the above configurations have been previously disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0105] Preferably, in any one of the winding portions, the inner passive region and the outer passive region have different axial thicknesses.

[0106] The technical effects and / or advantages and / or explanations of the above configurations have been previously disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0107] Preferably, in any said winding section, the thickness of the outer passive region is selected such that the ratio of its thickness to the thickness of the active region is less than or equal to 0.5.

[0108] The technical effects and / or advantages and / or explanations of the above configurations have been previously disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0109] The invention further relates to an electric machine comprising a bearing structure and a shaft guided by said bearing structure, along which are arranged coaxially at least one magnet module consisting of a plurality of permanent magnets and at least one coil module as disclosed within the scope of this specification.

[0110] Preferably, the electric machine comprises at least one coil module, preferably from 1 to 6 coil modules, very preferably from 1 to 3 coil modules. Preferably, the electric machine has one more magnet module than the number of coil modules.

[0111] The technical effects and / or advantages and / or explanations of the above configurations have been previously disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0112] The invention further relates to a vehicle or machine tool comprising an electric machine as disclosed herein.

[0113] The technical effects and / or advantages and / or explanations of the above configurations have been previously disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0114] One or more or all of the problems underlying the present invention are solved by the invention of a coil module disclosed hereinafter and / or an electric machine disclosed hereinafter and / or a vehicle or a machine tool disclosed hereinafter.

[0115] The coil modules described below include some of the configurations disclosed in relation to the coil modules described above, and therefore the technical effects, advantages, and explanations described above also apply to the corresponding configurations described below. In particular, the coil modules described below may preferably include any of the configurations described in relation to the coil modules described above.

[0116] The coil module for an electric machine according to the present invention comprises a first coil disk having a first coil carrier made of an electrically insulating material, at least one winding portion made of an electrically conductive material embedded in the first coil carrier, and a first ceramic boundary. The coil module further comprises a second coil disk having a second coil carrier made of an electrically insulating material, at least one winding portion made of an electrically conductive material embedded in the second coil carrier, and a second ceramic boundary. The first coil disk and the second coil disk are attached to each other in such a manner that a substantially annular cooling passage for a refrigerant is formed between the first coil disk and the second coil disk. The first ceramic boundary and the second ceramic boundary each at least partially form an inner wall of the substantially annular cooling passage. Preferably, the axial extension of the cooling passage is 1 mm to 2 mm.

[0117] The coil module, the first coil disc, the second coil disc, and the windings of the first and second coil discs may be configured as previously disclosed.

[0118] The first coil disk and the second coil disk, in particular the first coil carrier and the second coil carrier, are configured to define a substantially annular cooling passage therebetween when assembled and / or butted together, i.e., the cooling passage may be a space between the first coil disk and the second coil disk that is adapted and / or configured to convey a coolant to effectively remove heat from the first coil disk and / or the second coil disk.

[0119] For example, the first and / or second coil carriers may have a generally annular recess that defines the cooling passage when the first and second coil disks are assembled. For example, the first and second coil carriers may each have a contoured and / or thickened radially inner portion that abuts against one another when the first and second coil disks are assembled. The radially outer portions of the first and second coil carriers may be spaced apart from one another when the first and second coil disks are assembled to define the generally annular cooling passage. The cooling passage may be bounded radially outward by a further boundary, such as a radially outer ceramic boundary and / or coil carrier ring as described herein.

[0120] A "first ceramic interface" should be understood to refer to the structure of the ceramic material of the first coil disk that at least partially forms and / or lines the inner wall of the generally annular cooling channel. A "second ceramic interface" should be understood to refer to the structure of the ceramic material of the second coil disk that at least partially forms and / or lines the inner wall of the generally annular cooling channel. In other words, the first ceramic interface may separate the interior of the generally annular cooling channel from the first coil carrier, and the second ceramic interface may separate the interior of the generally annular cooling channel from the second coil carrier.

[0121] The ceramic interface can be provided in various ways. For example, the ceramic interface can be provided in the form of a disk of ceramic material arranged between the coil disks of the first and second coil carriers, respectively. The ceramic interface can also be provided in the form of a ceramic coating on the coil carrier. It is also possible to combine these, i.e. the ceramic interface can be provided partly in the form of a ceramic disk and partly in the form of a ceramic coating on the coil carrier.

[0122] The first and second ceramic interfaces may be two separate structures that are joined (e.g., glued) together when the first and second coil disks are assembled to form the inner wall of the generally annular cooling channel, and the first and second ceramic interfaces may be monolithic and / or integrally formed with one another.

[0123] Such a ceramic interface is advantageous in several respects. First, the ceramics contained in the ceramic interface are vapor-tight or substantially vapor-tight. Therefore, the ceramic interface does not absorb water and / or prevents water from the cooling channel from accumulating in the insulating material of the coil carrier. The ceramics generally exhibit high solvent and / or chemical resistance. Furthermore, the ceramics of the ceramic interface have a significantly higher thermal conductivity than the material of the coil carrier. For example, the thermal conductivity of ceramics is about 100 times that of plastics. Thus, the ceramic interface can improve the heat dissipation by the coolant in the cooling channel. Furthermore, ceramics are electrically insulating.

[0124] Thus, the first and second ceramic boundaries prevent the coolant in the cooling flow passage from contacting the first and second coil carriers and accumulating in the material of the first and second coil carriers. Such accumulation of the coolant can cause the material of the coil carrier to lose its insulating effect, for example, if the coolant contains water. However, since a voltage is applied to the coil during operation, sufficient electrical insulation must always be ensured between the winding and its surroundings. During direct cooling, the coolant contacts both the surroundings and the winding, so insulation must also be ensured here. Therefore, by providing the ceramic boundaries, it is possible to use a coolant containing water while reliably maintaining the insulating effect of the coil carrier for a long period of time. A coolant containing water is advantageous because water has a large heat capacity and excellent thermal conductivity. This makes it possible to improve the cooling of the coil disk of the electric machine and at the same time extend the life of the electric machine. At the same time, the heat dissipation of the coil disk is improved.

[0125] The ceramic interface also allows the thickness of the electrically insulating material of the coil carrier to be reduced, with the added benefit of improving the cooling capacity and efficiency of the electric machine.

[0126] Moreover, the ceramics at the ceramic boundary are mechanically very strong materials. Therefore, the ceramic boundary can impart or improve the mechanical strength and / or stability of the coil disk. The mechanical strength of the coil disk can prevent the coil disk from expanding in the axial direction due to the internal pressure of the refrigerant or the electromagnetic force acting on the coil module, which would cause the rotor to rub against the coil module. This not only ensures the mechanical strength of the coil disk through the ceramic boundary, but also makes it possible to select the material of the coil carrier with emphasis on thermal conductivity and heat resistance.

[0127] Preferably, the first and / or second ceramic boundaries consist of an aluminium-based and / or silicon-based ceramic, preferably a material selected from the group consisting of aluminium oxide, aluminium nitride, silicon carbide and silicon nitride.

[0128] The above ceramic materials are suitable for use as the ceramic boundary in terms of their properties, among which aluminum oxide is particularly suitable since it is widely used and easily available.

[0129] However, other ceramic materials may be used at the ceramic interface.

[0130] Preferably, the first ceramic interface forms an inner wall of the generally annular cooling passage over an entire radial area of ​​the generally annular cooling passage, and / or the second ceramic interface forms an inner wall of the generally annular cooling passage over an entire radial area of ​​the generally annular cooling passage.

[0131] That is, the first and second ceramic interfaces may form an inner wall of the generally annular cooling channel over an entire radial extent of the generally annular cooling channel, thus protecting material from the coolant over an entire radial extent of the cooling channel.

[0132] Preferably, the first ceramic interface comprises a first ceramic disc disposed on the first coil carrier, and preferably, the second ceramic interface comprises a second ceramic disc disposed on the second coil carrier.

[0133] Such a ceramic disk may be, for example, cut or stamped from a plate-shaped ceramic raw material.

[0134] The ceramic disk may be placed on the coil carrier after embedding (e.g., molding) of the windings and glued to the coil carrier during manufacture of the coil disk, or alternatively, the ceramic disk may be placed in a tool and molded together with the windings during molding of the windings to produce the coil carrier.

[0135] This makes it possible to make the manufacturing method of the coil module simple and efficient.

[0136] Preferably, the first ceramic disc and / or the second ceramic disc has a thickness of 0.1 mm to 1 mm, preferably 0.2 mm to 0.8 mm, more preferably 0.35 mm to 0.7 mm.

[0137] Such a thickness allows the ceramic boundary to minimize axial expansion of the coil disc while still providing interface with the coolant and strength to the coil disc.

[0138] Preferably, the first and second ceramic discs are integral and / or part of an integrally formed ceramic cooling passage.

[0139] That is, the ceramic cooling channel may be a three-dimensional hollow body formed as a unitary part and / or integrally with the first ceramic disc and the second ceramic disc. That is, the ceramic cooling channel may be in the form of an annular tube, and the cooling channel may be formed by the hollow space of the hollow body and / or the annular tube. Also, the ceramic cooling channel may be divided into a plurality of segments, which constitute the disk segments of the first ceramic disc and the disk segments of the second ceramic disc, respectively. Each of these segments may be in the form of a curved tube.

[0140] Preferably, the first ceramic disc comprises two or more, preferably two, three or four, ceramic disc segments and / or the second ceramic disc comprises two or more, preferably an even number, more preferably four, ceramic disc segments, which may be arranged adjacent to each other in each coil carrier.

[0141] Providing the ceramic disk in the form of a plurality of ceramic disk segments can simplify the manufacture of the ceramic disk, especially when the ceramic disk is of a certain size.

[0142] Preferably, the ceramic interface includes at least one ceramic seal member disposed on the ceramic disc segments to seal the interface between the ceramic disc segments.

[0143] That is, the ceramic disk segments may be arranged on the coil carrier such that one or more butt joints are formed between the ceramic disk segments. Preferably, these butt joints are sealed by arranging a ceramic seal member on the ceramic disk segments in the region of each butt joint. The ceramic seal member may be strip-shaped. The ceramic seal member may be attached to the ceramic disk by adhesive. Preferably, a ceramic seal member is arranged at each butt joint between the ceramic disk segments.

[0144] The ceramic seal member ensures a tight ceramic seal even in the area of ​​the butt joints between the ceramic disk segments.

[0145] Preferably, the first ceramic interface comprises a first ceramic coating applied to the first coil carrier, and preferably, the second ceramic interface comprises a second ceramic coating applied to the second coil carrier.

[0146] This allows the ceramic interface to be extremely thin, which, among other things, reduces the installation space of the coil module and increases the efficiency of the electric machine. Furthermore, coatings can exhibit high thermal conductivity. As such a coating can be applied directly, no additional adhesive layer is required between the coil carrier and the interface, allowing a further reduction in the installation space. As a result, the thermal resistance of the adhesive is also eliminated.

[0147] The coating may be applied by vapor deposition, preferably physical vapor deposition (PVD). The coating may also be applied by chemical vapor deposition (CVD), electroplating, or a sol-gel process.

[0148] Preferably, the first ceramic coating and / or the second ceramic coating has a thickness of 1 μm to 100 μm, preferably 1 μm to 50 μm, more preferably 1 μm to 30 μm.

[0149] Preferably, the first coil carrier and / or the second coil carrier have a generally annular recess. Also, in the present invention, the first ceramic interface and / or the second ceramic interface are provided in the form of a generally annular ceramic disk disposed in the generally annular recess of the first coil carrier and the second coil carrier, respectively.

[0150] The technical effects and / or advantages and / or explanations of the above configurations have been previously disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0151] The generally annular recess of the first coil carrier and / or the second coil carrier may be provided, for example, by making a radially inner region of the first and / or second coil carrier more undulating than a radially outer region of the first and / or second coil carrier, respectively, and / or by making the axial thickness of the coil carrier greater in the radially inner region than in the radially outer region. For example, the inner passive region of the windings disclosed herein may be located in the radially inner region of the coil carrier, while the active region and the outer passive region of the windings may be located in the radially outer region of the coil carrier. The generally annular ceramic disk may have a radially inner recess that is substantially aligned with the radially inner region of the coil carrier. The outer diameter of the annular ceramic disk may substantially match the diameter of the coil carrier.

[0152] Preferably, the coil module comprises at least one connecting element disposed within the generally annular cooling passage and bonded to both the first ceramic boundary and the second ceramic boundary, preferably integrally formed therewith.

[0153] That is, the at least one connecting element may connect the first ceramic boundary and the second ceramic boundary to each other. This can further increase the strength imparted to the coil disk or coil module by the ceramic boundary. At the same time, the connecting element can improve the heat dissipation from the coil disk by increasing the cooling surface of the cooling channel. The connecting element may also be arranged and / or configured in the cooling channel to generate turbulent flow of the coolant, which can further improve the heat dissipation.

[0154] For example, the connection element may be formed integrally and / or as a single piece with the ceramic interface, however, it is also possible for the connection element to be a separate component that is, for example, bonded to the ceramic interface.

[0155] Preferably, the at least one connecting element is made of an aluminium-based and / or silicon-based ceramic, preferably made of a material from the group consisting of aluminium oxide, aluminium nitride, silicon carbide and silicon nitride. Preferably, the at least one connecting element is bonded to the first ceramic boundary and / or the second ceramic boundary or is integrally formed at the first ceramic boundary and / or the second ceramic boundary.

[0156] Preferably, said at least one connecting element consists of a strut, preferably arranged perpendicular to said first and / or second coil disc.Preferably, said at least one connecting element consists of a rib running parallel to said first and / or second coil disc.

[0157] Such a connecting element can simultaneously improve the stability and cooling performance of the coil module.

[0158] Preferably, the coil module comprises a radially inner ceramic boundary, more preferably the radially inner ceramic boundary is flange-shaped and / or ring-shaped and is disposed radially adjacent to and inside the first ceramic boundary and the second ceramic boundary.

[0159] The radially inner ceramic interface can prevent a radially inner region of the coil carrier adjacent the cooling passage from contacting and absorbing the coolant.

[0160] The radially inner ceramic interface may be provided as a separate component, for example bonded to the first and / or second ceramic interface, or alternatively, may be configured as an integral and / or one-piece part formed with the first and / or second ceramic interface.

[0161] Preferably, the coil module comprises a radially outer ceramic boundary, which is preferably flange-shaped and / or ring-shaped and disposed radially adjacent to the outside of the first ceramic boundary and the second ceramic boundary.

[0162] The radially outer ceramic interface prevents the cooling flow passages from being forced radially outward and prevents the coolant from leaking radially outward into contact with and / or being absorbed by adjacent areas of the coil carrier.

[0163] The radially outer ceramic interface may be provided as a separate component, for example bonded to the first and / or second ceramic interface, or alternatively may be configured as an integral and / or one-piece part formed with the first and / or second ceramic interface.

[0164] Preferably, the first coil disk and / or the second coil disk have an inlet opening for introducing coolant into the generally annular cooling passage, and preferably, the first coil disk and / or the second coil disk have an outlet opening for removing coolant from the generally annular cooling passage.

[0165] The inlet and / or outlet openings may be provided in portions of the first and / or second coil disks located radially outside the coil carrier. For example, each coil disk may comprise a coil carrier ring arranged radially outside and / or around the coil carrier. The inlet and / or outlet openings may be provided in the coil carrier ring. The inlet and / or outlet openings may be in the form of axial holes. The inlet openings allow the coolant to flow into the cooling channels, through the cooling channels and out of the outlet openings. Preferably, the inlet and outlet openings are offset by 180° with respect to the axis of the coil module.

[0166] Guiding the coolant in this manner has been found to be advantageous both from the standpoint of cooling function and of manufacturing the coil module.

[0167] Preferably, the first coil carrier has a plurality of windings of conductive material embedded therein, each of the windings being embedded in a circumferential direction around a center of the first coil carrier, and the second coil carrier has a plurality of windings of conductive material embedded therein, each of the windings being embedded in a circumferential direction around a center of the second coil carrier, and each of the windings has two active regions extending radially from the center and two passive regions extending tangentially at radially outer and inner edges.

[0168] Preferably, in a plan view of the coil disk, the active regions of the different winding sections do not overlap one another, whereas each passive region of any one of the winding sections partially overlaps a corresponding passive region of two immediately adjacent winding sections, and the axial cross-sectional thickness of each of the winding sections is greater in the active regions than in the passive regions.

[0169] The technical effects and / or advantages and / or explanations of the above configurations have been previously disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0170] Preferably, adjacent active areas of each of the plurality of winding portions of the first coil disk and the second coil disk are tangentially spaced apart from each other such that a gap is located between the adjacent active areas, and the first ceramic boundary portion and the second ceramic boundary portion each have a protrusion extending into the gap located between the adjacent active areas.

[0171] That is, adjacent active areas of each of the plurality of winding portions may be spaced apart such that the first coil carrier and the second coil carrier each have gaps between adjacent active areas of each of the plurality of winding portions, and protrusions of the first and second ceramic interfaces may extend axially into the gaps.

[0172] Preferably, the gaps and protrusions are in the form of a sector, ie a "slice of a pie".

[0173] The projection may be part of the ceramic interface or may be inserted as a separate entity into the gap and optionally bonded to the ceramic interface. The projection may contain or consist of the same ceramic material as the ceramic interface, but may also contain or consist of a different material.

[0174] Besides, such protrusions can further increase the stability of the coil disk and / or further strengthen it. As a result, the load due to the internal pressure of the coolant in the cooling channels can be better absorbed. It is also possible to form a fit between the protrusions at the ceramic interface and the gaps of the coil carrier, which can absorb torque. For example, a torque is generated between the rotor and the windings of the stator (i.e. the coil module) due to electromagnetic interaction. However, this torque causes rotation in the rotor, but needs to be dissipated in the stator. The above-mentioned "slice of the pie" configuration allows the form fit between the coil carrier and the ceramic interface to dissipate torque from the coil carrier to the ceramic interface. From the ceramic interface, the torque can then be transferred to the housing of the coil module or to the electric machine, respectively. In this way, deformations of the windings, in particular of the active area of ​​the windings, can be prevented. The protrusions can also improve heat dissipation from the windings. This makes it possible to significantly improve the cooling performance.

[0175] Preferably, said cooling channels are located at least in a radially extending portion of said active region, and preferably also in a radially outer portion of said passive region.

[0176] That is, the cooling channels may extend over at least the radial portion of the first and second coil disks where the active regions of the windings are located. Since most of the heat is generated in the active regions of the windings, this can improve heat dissipation. Preferably, the cooling channels extend over at least the entire radial region of the first and second coil disks where the entire active regions of the windings are located.

[0177] Preferably, an axial thickness of the active area of ​​each winding portion of the first and / or second coil disc decreases in a radially outward direction, and preferably a tangential width of the active area of ​​each winding portion of the first and / or second coil disc increases in a radially outward direction.

[0178] The technical effects and / or advantages and / or explanations of the above configurations have been previously disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0179] Preferably, in the region of the active area, the axial depth of the recess increases in the radially outward direction.

[0180] The technical effects and / or advantages and / or explanations of the above configurations have been previously disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0181] Preferably, in each of the winding sections, a ratio of a thickness of the passive region to a thickness of the active region is less than 1. Preferably, in each of the winding sections, a ratio of a thickness of the passive region to a thickness of the active region is greater than or equal to 0.3 and less than 1.

[0182] The technical effects and / or advantages and / or explanations of the above configurations have been previously disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0183] Preferably, the cross-sectional shape of each of said winding portions changes when transitioning from the active region to the passive region.

[0184] The technical effects and / or advantages and / or explanations of the above configurations have been previously disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0185] Preferably, the active areas of the separate winding portions of the first coil disk are entirely located on the same plane in a side view. Preferably, the active areas of the separate winding portions of the second coil disk are entirely located on the same plane in a side view.

[0186] The technical effects and / or advantages and / or explanations of the above configurations have been previously disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0187] Preferably, the winding portion is composed of a thin strand of a plurality of wires, each of which is electrically insulated from the others and has a wire diameter of 0.1 mm or less.

[0188] The technical effects and / or advantages and / or explanations of the above configurations have been previously disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0189] Preferably, the number of windings of the first coil disc and / or the second coil disc, respectively, corresponds to an integer multiple of three to enable three-phase operation.

[0190] The technical effects and / or advantages and / or explanations of the above configurations have been previously disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0191] Preferably, in any said winding section, the inner passive area and the outer passive area have different axial thicknesses. Preferably, in any said winding section, the thickness of the outer passive area is selected such that the ratio of its thickness to the thickness of the active area is less than or equal to 0.5.

[0192] The technical effects and / or advantages and / or explanations of the above configurations have been previously disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0193] The invention further relates to an electric machine comprising a bearing structure and a shaft guided by said bearing structure, along which are arranged coaxially at least one magnet module consisting of a plurality of permanent magnets and at least one coil module as disclosed within the scope of this specification.

[0194] The technical effects and / or advantages and / or explanations of the above configurations have been previously disclosed elsewhere herein and apply equally to each of the configurations described herein.

[0195] The invention further relates to a vehicle or machine tool equipped with an electric machine as disclosed within the present specification.

[0196] Further preferred embodiments of the present invention are disclosed in the following numbered paragraphs:

[0197] [Item 1] at least one coil disk (6) having at least one coil carrier (15) made of an electrically insulating material with a plurality of respective windings (13) made of an electrically conductive material, the windings being disposed on the at least one coil carrier (6) in a circumferential direction around a center portion (14) of the at least one coil carrier (6); Equipped with Each of the windings (13) has two active regions (16) extending radially from the central portion (14) and two passive regions (17a, 17b) extending tangentially at the radially outer and inner edges, A coil module (18) for an electric machine, in which, in a plan view of the coil disk (6), the active areas (16) of different winding sections (13) do not overlap each other, whereas each passive area (17a, 17b) of any one of the winding sections (13) partially overlaps a corresponding passive area (17a, 17b) of two immediately adjacent winding sections (13), A coil module (18), characterized in that the axial thickness of the cross section of each of the winding portions (13) is thicker in the active region (16) than in the passive regions (17a, 17b).

[0198] [Item 2] The coil module (18) described in item 1, characterized in that in each winding section (13), the ratio of the thickness of the passive area (17a, 17b) to the thickness of the active area (16) is less than 1.

[0199] [Item 3] The coil module (18) according to item 1 or 2, characterized in that in each of the winding portions (13), the ratio of the thickness of the passive region (17a, 17b) to the thickness of the active region (16) is greater than or equal to 0.3 and less than 1.

[0200] [Item 4] 4. The coil module according to any one of claims 1 to 3, characterized in that the cross-sectional shape of each of the winding sections (13) changes at a transition section from an active area (16) to a passive area (17a, 17b).

[0201] [Item 5] A coil module (18) according to any one of items 1 to 4, characterized in that the active areas (16) of the separate winding portions (13) are all entirely located on the same plane when viewed from the side.

[0202] [Item 6] A coil module (18) according to any one of items 1 to 5, characterized in that the axial thickness of the active area (16) of each of the winding portions (13) decreases in the radially outward direction, and the tangential width of the active area (16) of each of the winding portions (13) increases in the radially outward direction.

[0203] [Item 7] 7. The coil module (18) according to any one of items 1 to 6, characterized in that the winding portion is composed of a thin twisted wire of multiple strands, each strand having a wire diameter of 0.1 mm or less, that are electrically insulated from one another.

[0204] [Item 8] 8. The coil module (18) according to any one of items 1 to 7, wherein the number of the winding portions (13) corresponds to an integer multiple of 3 so as to enable three-phase operation.

[0205] [Item 9] The coil module (18) according to any one of items 1 to 8, characterized in that in any one of the winding portions (13), the axial thickness of an inner passive region (17a) and an outer passive region (17b) is different.

[0206] [Item 10] Item 9. The coil module according to claim 9, wherein in any of the winding sections (13), the thickness of the outer passive area (17) is selected so that the ratio of the thickness of the area to the thickness of the active area (16) is 0.5 or less.

[0207] [Item 11] A bearing structure (1, 3), A shaft (2) guided by the bearing structure (1, 3); and arranged coaxially along the shaft (2) are at least one magnet module (4) consisting of a plurality of permanent magnets (5) and at least one coil module (18) according to any one of claims 1 to 10.

[0208] [Item 12] Item 12. The electric machine according to claim 11, wherein at least one of the coil modules (18) is covered with a film made of an electrically insulating material at least on the side facing the magnet module (4).

[0209] [Item 13] 13. The electric machine according to claim 11 or 12, characterized in that the at least one coil module (18) has at least two interconnected coil disks (6) and a cooling passage formed in the space between the two coil disks.

[0210] [Item 14] A vehicle or machine tool equipped with an electric machine according to any one of items 11 to 13.

[0211] [Item 15] A coil module (18) for an electric machine, in particular a coil module according to any one of the preceding claims, comprising: a first coil disk (6) having at least one winding portion (13) made of a conductive material; a second coil disk (6) having at least one winding portion (13) made of a conductive material; wherein the first coil disk (6) and / or the second coil disk (6) have a generally annular recess (22), and the first coil disk (6) and the second coil disk (6) are attached to each other such that a generally annular cooling flow passage (23) for a refrigerant is formed between the first coil disk (6) and the second coil disk (6) by the generally annular recess (22).

[0212] [Item 16] In the coil module (18) according to item 15, the first coil disk (6) and / or the second coil disk (6) have an inlet opening (43) in a portion of the recess (22) so as to guide a coolant into the substantially annular cooling passage (23), and / or A coil module (18), wherein the first coil disk (6) and / or the second coil disk (6) have an outlet opening (45) in the recess (22) to direct coolant out of the generally annular cooling passage (23).

[0213] [Item 17] In the coil module (18) described in item 16, the first coil disk (6) and / or the second coil disk (6) have webs (38a, 38b) within the recess (22) between the inlet opening (43) and the outlet opening (45) configured to partition the approximately annular cooling flow passage (23) between the inlet opening (43) and the outlet opening (45).

[0214] [Item 18] In the coil module (18) according to any one of items 15 to 17, the first coil disk (6) and the second coil disk (6) each have At least one coil carrier (15) made of an electrically insulating material; and a plurality of winding portions (13) made of a conductive material and provided on the at least one coil disk (6) in a circumferential direction around a center portion (14) of the at least one coil disk (6); Including, Each of the windings (13) has two active regions (16) extending radially from the central portion (14) and two passive regions (17b) extending tangentially at the radially outer and inner edges, In a plan view of the coil disk (6), the active regions (16) of different winding portions (13) do not overlap each other, whereas each passive region (17a, 17b) of any one of the winding portions (13) partially overlaps a corresponding passive region (17a, 17b) of two immediately adjacent winding portions (13); A coil module (18), characterized in that the axial thickness of the cross section of each of the winding portions (13) is thicker in the active region (16) than in the passive regions (17a, 17b).

[0215] [Item 19] A coil module according to item 18, wherein the recess (22) is located at least in the region of the radially extending active region (16), and preferably also in the region of the radially outer passive region (17b).

[0216] [Item 20] In the coil module (18) according to item 19, an axial thickness of the active area (16) of each of the winding portions (13) of the first and / or second coil disks (6) decreases in a radially outward direction; A coil module (18) in which the tangential width of the active area (16) of each of the winding portions (13) of the first and / or second coil disks (6) increases in a radially outward direction.

[0217] [Item 21] 21. The coil module (18) according to item 20, wherein in the active region (16), the axial depth (34, 34a, 34b) of the recess increases radially outward.

[0218] [Item 22] A coil module (18) according to any one of items 18 to 21, wherein in each winding section (13), the ratio of the thickness of the passive area (17a, 17b) to the thickness of the active area (16) is less than 1.

[0219] [Item 23] 23. The coil module (18) according to any one of items 18 to 22, wherein in each winding portion (13), the ratio of the thickness of the passive region (17a, 17b) to the thickness of the active region (16) is greater than or equal to 0.3 and less than 1.

[0220] [Item 24] A coil module (18) according to any one of items 18 to 23, wherein the cross-sectional shape of each of the winding sections (13) changes at the transition section from the active area (16) to the passive area (17a, 17b).

[0221] [Item 25] A coil module (18) according to any one of items 18 to 24, characterized in that the active areas (16) of the separate winding sections (13) are all located on the same plane when viewed from the side.

[0222] [Item 26] 26. The coil module (18) according to any one of items 18 to 25, characterized in that the winding portion is composed of a thin twisted wire of multiple wires, each wire having a wire diameter of 0.1 mm or less, that are electrically insulated from each other.

[0223] [Item 27] 27. The coil module (18) according to any one of items 18 to 26, characterized in that the number of the winding portions (13) corresponds to an integer multiple of 3 so as to enable three-phase operation.

[0224] [Item 28] A coil module (18) according to any one of items 18 to 27, characterized in that in any of the winding portions (13), the axial thickness of an inner passive region (17a) and an outer passive region (17b) are different.

[0225] [Item 29] 29. The coil module according to claim 28, wherein in any of the winding sections (13), the thickness of the outer passive area (17b) is selected so that the ratio of the thickness of said area to the thickness of the active area (16) is 0.5 or less.

[0226] [Item 30] A bearing structure (1, 3), A shaft (2) guided by the bearing structure (1, 3); and arranged coaxially along the shaft (2) are at least one magnet module (4) consisting of a plurality of permanent magnets (5) and at least one coil module (18) according to any one of items 15 to 29.

[0227] [Item 31] A vehicle (150) or a machine tool (154) equipped with the electric machine according to item 30.

[0228] Further preferred embodiments of the present invention are disclosed in the following numbered aspects:

[0229] [Aspect 1] A coil module (18) for an electric machine, in particular a coil module according to any one of the preceding claims, comprising: a first coil disk (6, 6a) having a first coil carrier (15, 15a) made of an electrically insulating material, at least one winding portion (13) made of an electrically conductive material embedded in the first coil carrier (15, 15a), and a first ceramic boundary portion (56, 56a); a second coil disc (6, 6b) having a second coil carrier (15, 15b) made of an electrically insulating material, at least one winding portion (13) made of an electrically conductive material embedded in the second coil carrier (15, 15b), and a second ceramic boundary portion (56, 56b); Equipped with the first coil disk (6, 6a) and the second coil disk (6, 6b) are configured and attached to each other such that a substantially annular cooling passage (23) for a refrigerant is formed between the first coil disk (6, 6a) and the second coil disk (6b); The first ceramic boundary (56, 56a) and the second ceramic boundary (56, 56b) each at least partially form an inner wall of the generally annular cooling passage (23).

[0230] [Aspect 2] In the coil module (18) described in aspect 1, the first and / or second ceramic boundary portions (56, 56a, 56b) are made of aluminum-based and / or silicon-based ceramics, preferably made of a material selected from the group consisting of aluminum oxide, aluminum nitride, silicon carbide and silicon nitride.

[0231] [Aspect 3] and / or wherein the first ceramic interface (56, 56a) forms an inner wall of the generally annular cooling channel (23) over an entire radial area of ​​the generally annular cooling channel. The coil module (18), wherein the second ceramic boundary portion (56, 56b) forms an inner wall of the generally annular cooling passage (23) over an entire radial area of ​​the generally annular cooling passage.

[0232] [Aspect 4] The coil module (18) according to any one of the first to third aspects, wherein the first ceramic interface (56, 56a) comprises a first ceramic disk disposed on the first coil carrier (15, 15a); and / or A coil module (18), wherein the second ceramic interface (56, 56b) comprises a second ceramic disc disposed on the second coil carrier (15, 15b).

[0233] [Aspect 5] In the coil module (18) according to aspect 4, the first ceramic disc (56, 56a) and / or the second ceramic disc (56, 56b) has a thickness of 0.1 mm to 1 mm, preferably 0.2 mm to 0.8 mm, and more preferably 0.35 mm to 0.7 mm.

[0234] [Aspect 6] A coil module (18) according to aspect 4 or 5, wherein the first ceramic disk and the second ceramic disk are part of a ceramic cooling passage formed as an integral piece.

[0235] [Aspect 7] In the coil module (18) according to any one of aspects 4 to 6, the first ceramic disc (56, 56a) is composed of two or more, preferably an even number, more preferably four ceramic disc segments; and / or A coil module (18), wherein the second ceramic disc (56, 56b) is made up of two or more, preferably an even number, and more preferably four ceramic disc segments.

[0236] [Aspect 8] In the coil module (18) described in embodiment 7, the ceramic interface includes at least one ceramic seal member disposed on the ceramic disk segments to seal the joint between the ceramic disk segments.

[0237] [Aspect 9] A coil module (18) as described in any one of aspects 1 to 3, wherein the first ceramic boundary portion (56, 56a) is made of a ceramic coating applied to the first coil carrier (15, 15a) and / or the second ceramic boundary portion (56, 56b) is made of a ceramic coating applied to the second coil carrier (15, 15b).

[0238] [Aspect 10] In the coil module (18) described in aspect 9, the first ceramic coating and / or the second ceramic coating has a thickness of 1 μm to 100 μm, preferably 1 μm to 50 μm, and more preferably 1 μm to 30 μm.

[0239] [Aspect 11] In the coil module (18) according to any one of the first to tenth aspects, the first coil carrier (15, 15a) and / or the second coil carrier (15, 15b) have a substantially annular recess (22); A coil module (18), wherein the first ceramic boundary portion (56, 56a) and / or the second ceramic boundary portion (56, 56b) are provided in the form of a generally annular ceramic disk disposed within the generally annular recess (22) of the first coil carrier and / or the second coil carrier.

[0240] [Aspect 12] The coil module (18) according to any one of the first to eleventh aspects, further comprising: at least one connecting element (63, 64) disposed within the generally annular cooling channel (23) and connected to both the first ceramic boundary (56, 56a) and the second ceramic boundary (56, 56b), preferably integrally formed therewith; A coil module (18).

[0241] [Aspect 13] In the coil module (18) according to aspect 12, preferably, the at least one connecting element (63, 64) is made of an aluminum-based and / or silicon-based ceramic, preferably made of a material selected from the group consisting of aluminum oxide, aluminum nitride, silicon carbide and silicon nitride, and / or A coil module (18), wherein the at least one connection element (63, 64) is bonded to the first ceramic boundary and / or the second ceramic boundary or is integrally formed at the first ceramic boundary and / or the second ceramic boundary.

[0242] [Aspect 14] In the coil module according to aspect 12 or 13, the at least one connecting element (63, 64) is made of a strut, preferably arranged perpendicular to the first and / or second coil disk (6, 6a, 6b), and / or A coil module, wherein said at least one connecting element (63, 64) consists of a rib extending parallel to said first and / or second coil disc (6, 6a, 6b).

[0243] [Aspect 15] The coil module (18) according to any one of the first to fourteenth aspects, further comprising: A radially inner ceramic boundary (57); Equipped with Preferably, the radially inner ceramic boundary portion (57) is flange-shaped and / or ring-shaped and is disposed adjacent to the inside of the first ceramic boundary portion (56, 56a) and the second ceramic boundary portion (56, 56b) in the radial direction of the coil module (18).

[0244] [Aspect 16] The coil module (18) according to any one of the first to fifteenth aspects, further comprising: A radially outer ceramic boundary (58); Equipped with Preferably, the radially outer ceramic boundary portion (58) is flange-shaped and / or ring-shaped and is disposed radially adjacent to the outside of the first ceramic boundary portion (56, 56a) and the second ceramic boundary portion (56, 56b), in the coil module (18).

[0245] [Aspect 17] In the coil module (18) of any one of the first to sixth aspects, the first coil disk (6, 6a) and / or the second coil disk (6, 6b) have inlet openings (43, 54) for introducing a coolant into the generally annular cooling channel (23); and / or A coil module (18), wherein the first coil disk (6, 6a) and / or the second coil disk (6, 6b) have outlet openings (45, 55) through which refrigerant is discharged outside the generally annular cooling passage (23).

[0246] [Aspect 18] In the coil module (18) according to any one of claims 1 to 17, a plurality of winding portions (13) made of a conductive material are embedded in the first coil carrier (15, 15a), and the winding portions (13) are embedded in the first coil carrier (15, 15a) in a circumferential direction around a center portion (14) of the first coil carrier (15, 15a); a plurality of winding portions (13) made of a conductive material are embedded in the second coil carrier (15, 15b), and each of the winding portions (13) is embedded in the second coil carrier (15, 15b) in a circumferential direction around a center portion (14) of the second coil carrier (15, 15b); Each of the windings (13) has two active regions (16) extending radially from the central portion (14) and two passive regions (17b) extending tangentially at the radially outer and inner edges, A coil module (18) in which, in a plan view of the coil disk (6, 6a, 6b), the active regions (16) of different winding portions (13) do not overlap with each other, whereas each passive region (17a, 17b) of any one of the winding portions (13) partially overlaps with the corresponding passive regions (17a, 17b) of two immediately adjacent winding portions (13), and the axial thickness of the cross section of each of the winding portions (13) is greater in the active region (16) than in the passive regions (17a, 17b).

[0247] [Aspect 19] In the coil module (18) according to aspect 18, adjacent active areas (16) of each of the plurality of winding portions (13) of the first coil disk (6, 6a) and the second coil disk (6, 6b) are spaced apart from each other in a tangential direction such that a gap is located between the adjacent active areas (16); a coil module (18) wherein the first ceramic boundary portion (56, 56a) and the second ceramic boundary portion (56, 56b) each have a protrusion (65) extending into the gap located between the adjacent active regions (16).

[0248] [Aspect 20] A coil module (18) as described in aspect 18 or 19, wherein the cooling flow path (23) is located at least in the region of the radially extending active region (16), and preferably also in the region of the radially outer passive region (17b).

[0249] [Aspect 21] In the coil module (18) according to aspect 20, an axial thickness of the active area (16) of each of the winding portions (13) of the first and / or second coil disks (6) decreases in a radially outward direction; A coil module (18) in which the tangential width of the active area (16) of each of the winding portions (13) of the first and / or second coil disks (16) increases in a radially outward direction.

[0250] [Aspect 22] A coil module (18) as described in aspect 21, wherein in the active region (16), the axial depth (34, 34a, 34b) of the recess (22) increases in a radially outward direction.

[0251] [Aspect 23] In the coil module (18) according to any one of aspects 18 to 22, in each of the winding portions (13), a ratio of a thickness of the passive region (17a, 17b) to a thickness of the active region (16) is less than 1; Preferably, in the coil module (18), the ratio of the thickness of the passive regions (17a, 17b) to the thickness of the active region (16) in each of the winding portions (13) is 0.3 or more and less than 1.

[0252] [Aspect 24] A coil module (18) described in any one of aspects 18 to 23, wherein the cross-sectional shape of each winding section (13) changes at the transition section from the active region (16) to the passive region (17a, 17b).

[0253] [Aspect 25] In the coil module (18) according to any one of the aspects 18 to 24, the active areas (16) of the separate winding portions (13) of the first coil disk (15) are all located on the same plane in a side view, and / or A coil module (18) in which the active areas (16) of the separate winding portions (13) of the second coil disk (15) are all located on the same plane when viewed from the side.

[0254] [Aspect 26] A coil module (18) according to any one of aspects 18 to 25, wherein the winding portion is composed of a thin twisted wire of multiple wires, each wire having a wire diameter of 0.1 mm or less, that are electrically insulated from each other.

[0255] [Aspect 27] In the coil module (18) described in any one of aspects 18 to 26, the number of winding portions (13) of the first coil disk (15) and / or the second coil disk (15) each corresponds to an integer multiple of three to enable three-phase operation.

[0256] [Aspect 28] In the coil module (18) according to any one of aspects 18 to 27, in any one of the winding portions (13), an axial thickness of an inner passive region (17a) is different from that of an outer passive region (17b), Preferably, in any one of the winding sections (13), the thickness of the outer passive area (17b) is selected such that the ratio of the thickness of said area to the thickness of the active area (16) is 0.5 or less.

[0257] [Aspect 29] A bearing structure (1, 3), A shaft (2) guided by the bearing structure (1, 3); and arranged coaxially along the shaft (2) are at least one magnet module (4) consisting of a plurality of permanent magnets (5) and at least one coil module (18) according to any one of the first to second aspects.

[0258] [Aspect 30] A vehicle (150) or a machine tool (154) equipped with an electric machine according to embodiment 29.

[0259] Exemplary embodiments of the invention are illustrated in and described below with reference to the following drawings: FIG. [Brief description of the drawings]

[0260] [Figure 1] FIG. 2 is an exploded view of the electric motor. [Diagram 2] FIG. 2 is a plan view of a coil disk. [Diagram 3] FIG. 2 is a side view of the coil module. [Figure 4] 4A and 4B are a plan view and a cross-sectional view of a winding portion. [Diagram 5] FIG. 2 is a plan view of the coil module. [Figure 6] FIG. 2 is a cross-sectional view of the coil module. [Figure 7] FIG. 2 is a plan view of a coil disk. [Figure 8A] FIG. 2 is a cross-sectional view of a coil disk. [Figure 8B] FIG. 4 is another cross-sectional view of the coil disk. [Figure 8C] FIG. 11 is yet another cross-sectional view of the coil disc. [Figure 8D] FIG. 11 is yet another cross-sectional view of the coil disc. [Figure 9A] FIG. [Figure 9B] FIG. [Figure 10] FIG. 2 is a cross-sectional view of a coil module. [Figure 11A] FIG. 2 is a plan view of the first coil disk. [Figure 11B] FIG. 4 is a plan view of the second coil disk. [Figure 12A] FIG. 2 is a perspective view of a coil module. [Figure 12B] FIG. 12B is a plan view of the coil module shown in FIG. 12A. [Figure 12C] FIG. 12B is a perspective view of a portion of the coil module shown in FIG. 12A. [Figure 13A] FIG. [Figure 13B] FIG. [Figure 13C] FIG. 13C is a cross-sectional view taken along plane AA of FIG. 13B. [Figure 13D] FIG. 13C is a cross-sectional view taken along plane BB of FIG. 13B. [Figure 14A] FIG. 1 shows a coil disk without a ceramic boundary. [Figure 14B] FIG. 1 shows a coil disk with a ceramic boundary. [Figure 15A] FIG. 2 shows a ceramic interface with a connecting element. [Figure 15B] FIG. 13 is another view of a ceramic interface with connecting elements. [Figure 16] FIG. 1 shows a ceramic interface with protrusions. [Figure 17] FIG. [Figure 18] FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0261] 1 shows an exploded view of an electric motor. A first bearing shield 1 together with a second bearing shield 3 constitutes a bearing arrangement for a motor shaft 2. The motor shaft 2 is guided in the center of the bearing shields 1, 3, a bearing cap 7 and a fixed bearing 8 are provided in the area of ​​the first bearing shield 1, and a floating bearing 12 is provided in the area of ​​the second bearing shield 3. In the illustrated embodiment, the bearing shields 1, 3, the bearing cap 7, the coil spacer 10 and the magnet spacer 9 are made of polyamide, the motor shaft 2 is made of stainless steel, and the fixed bearing 8 and the floating bearing 12 are deep groove ball bearings made of steel.

[0262] Between the first bearing shield 1 and the second bearing shield 3, a coil module 18 consisting of two coil disks 6 arranged axially one above the other and a magnet disk or magnet module 4 can be seen, which are spaced apart from each other by a coil spacer 10 and a magnet spacer 9. The coil module 18 is disk-shaped, i.e. its length and width are significantly greater than its thickness (measured in the axial direction in FIG. 1). The expression "significantly greater" is understood to mean that the thickness is less than or equal to 10% of the length and width, respectively. In general, the length and width are equal. In the illustrated embodiment, the coil module 18 is arranged above the motor shaft 2 and serves as a stator adjacent to the two magnet disks or magnet modules 4 which serve as a rotor. The stator is located between the two magnet disks 4. Furthermore, in the embodiment shown in FIG. 1, an iron return yoke 11 is provided between the magnet disks 4 and the second bearing shield 3. However, in further embodiments, the iron return yoke 11 may be omitted or replaced by another one.

[0263] The magnet disks 4 are made of a material that is not magnetizable and preferably is also non-conductive, for example aluminum, and are attached to the motor shaft 2, which is inserted in the bearings 8, 12 of the bearing shields 1, 3. The motor shaft 2 is further fitted with magnet spacers 9 which form gaps between the magnet disks 4 for arranging the coil modules 18. The permanent magnets 5 are arranged on the magnet disks 4 in alternating radial and circumferential directions, i.e. so that the north and south poles always face alternately in the direction of the stator (i.e. in the axial direction). In this case, the number of permanent magnets 5 is always an even number. Preferably, the number of permanent magnets 5 is exactly twice the number of windings of each phase.

[0264] In the embodiment shown in FIG. 1, one coil module 18 consisting of two coil disks 6 may be provided. However, it is also possible to connect three or more such coil disks 6 to one another to form a coil module 18. In operation, a cooling medium may be passed through the spaces between the coil disks 6. The simplest (but still efficient) structure of the motor is a single coil module 18 with one coil disk 6 and two magnet disks 4, but it is also possible to envisage an appropriate increase in the number of coil modules 18 and magnet disks 4. Preferably, the number of magnet disks 4 is one more than the number of coil modules 18. The variable number of coil modules 18 and magnet disks 4 installed offers the advantages of a corresponding modular design, in particular in combination with the corresponding shaft and bearing design. In addition to the combination of two types of modules, coil module 18 and magnet disk 4, the individual modules can be modified to provide additional flexibility in the design of the motor. The coil modules 18 and magnet disks 4 can be adjusted separately. For example, there may be cases where only the permanent magnet 5 needs to be adjusted, and the rest of the structure remains unchanged.

[0265] FIG. 2 shows the coil carrier 15 on which the windings 13 are provided and which constitutes the coil disk 6, in plan view, i.e. along a normal direction perpendicular to both the length and width of the coil module 18. In the following figures, the same components / elements as in this figure are designated by the same reference numerals. The coil carrier 15 is made of an electrically insulating material and is round in plan view, i.e. the length and width are completely the same. A number of windings 13 are provided radially on the coil carrier 15 in the circumferential direction around a center 14 of the coil carrier 15. Each winding 13 is electrically insulated from the immediately adjacent winding 13. The center 14 of the coil carrier 15 crosses the axis of rotation of the electric machine. In the embodiment shown in FIG. 2, the windings 13 are three-phase windings. Each winding 13 is made of several turns of twisted wire. That is to say, each winding 13 is identical in design to the three windings 13 following it within a certain group unit. Moreover, these winding sections 13 are provided in the same depth direction and arrangement configuration: the first phase is composed of the winding section 13 that can be seen as the top layer in Figure 1, the second phase is composed of the winding section 13 that is half hidden when viewed from above, and the third phase is composed of the winding section 13 that is completely hidden when viewed from above.

[0266] Each winding section 13 has two active areas 16 extending radially from the center 14 of the coil disk 6 and contributing to the torque of the motor, and two passive areas 17a, 17b (i.e., the radially inner passive area 17a and the radially outer passive area 17b) extending approximately tangentially at the radially outer and inner edges. Thus, the inner passive area 17a, which is provided closer to the center 14 than the outer passive area 17b, is shorter in length than the outer passive area 17b. In a plan view, i.e., from a viewpoint along the motor shaft 2, the active areas 16 of different winding sections 13 do not overlap each other, whereas the inner and outer passive areas 17a, 17b of any winding section 13 are partially covered by the corresponding passive areas 17a, 17b of the two immediately adjacent winding sections 13, respectively.

[0267] Circles K1 and K2 represent the radially inner and outer boundaries of the active area 16. That is, the active area 16 extends from the inner circle K1 to the outer circle K2. The areas of the windings outside the circles K1 and K2 are allocated to passive areas 17a and 17b.

[0268] In the embodiment shown in Fig. 2, each of the three phases is formed by an individual tooth, i.e. an individual winding section 13. Each winding section 13 is wound several times, but may also be provided with only one turn. What is special is that the different phases of spoke-like active areas 16 are adjacent to each other in the same plane. In Fig. 2, these active areas 16 are indicated by two circular lines on the winding section 13, i.e. the active areas 16 have the same shape and dimensions, while the passive areas 17a and 17b have different shapes and dimensions.

[0269] The passive areas 17a, 17b always form an overlap between two adjacent teeth. This means that the plane of each phase must be displaced. In the case of direct overlap without changing the cross section, the axial thickness of the coil disc 6 would be doubled in the area of ​​the passive areas 17a, 17b. As a result, the axial spacing between the permanent magnets 5 can be increased depending on the change in the cross section of the winding 13, i.e. the change in the thickness-to-width ratio or the height-to-width ratio of the winding 13. In the illustrated embodiment, the ratio of the thickness of the active area 16 to the thickness of the passive areas 17a, 17b in each winding 13 is exactly 2. Simply put, if the active regions 16 are normalized to have a thickness or height in the axial direction of 1 (note that in the illustrated embodiment, all active regions 16 have the same thickness), and the passive regions 17a, 17b have a thickness of 0.75 (note that in the illustrated embodiment, all passive regions 17a, 17b have the same thickness), the passive regions 17a, 17b will have a thickness less than the normalized thickness. However, since the passive regions 17a, 17b are arranged side by side, overlapping each other, the combined thickness of the passive regions 17a, 17b is 1.5 in side view. Such an arrangement is depicted, for example, in the cross-sectional view on the right side of FIG. 2. The passive regions 17a, 17b are individually smaller in thickness or height than the active region 16, but appear thicker due to the overlapping arrangement of the windings 13 due to the overlapping portions. This provides a sufficient installation space between the active area 16, allowing the permanent magnet 5 to be brought closer to the active area 16. The trajectory of the outer passive area 17b is shown in the lower part of FIG. 2. It is clear that the plane of the passive area 17b is displaced for every third winding section. In the illustrated embodiment, the number of winding sections 13 corresponds to an integer multiple of three, so as to enable three-phase operation. That is, the winding sections 13 form a total of three rows of different phases, and the active areas 16 of the winding sections 13 are entirely on the same plane in side view, while the passive areas 17a, 17b are distributed on two planes. The two phases are on the same plane, but the third phase is displaced to another plane.

[0270] For example, the two phases may be overlapped (i.e., juxtaposed) radially, not axially, by an appropriate change in cross section. As a result, the coil disc 6 expands radially. By doubling the radial height or thickness of the passive areas 17a, 17b, the axial doubling caused by the two phases is eliminated, so that the entire coil disc 6 is located on the same plane. As a result, a three-phase winding cored coil module 18 for a cored axial flux electric motor is obtained, in which the change in the cross section of the windings 13 can be adjusted (i.e., the axial height of the coil module 18 can be adjusted).

[0271] 2, eight winding portions 13 arranged in a circle and electrically connected in series constitute one coil. Three sets of such coils are combined with the coil disk 6 and the coil carrier 15 of the coil module 18 in correspondence with three-phase current.

[0272] In a further embodiment, it is also possible to obtain a coil module 18 by joining or connecting two or more coil disks 6 together by material or frictional engagement. The amount of space between the active areas 16 can be adjusted by varying the cross-section of the coil structure formed by the windings 13.

[0273] 2, the coil carrier 15 is configured to form a cooling flow path when two coil carriers 15 are stacked together. Additionally, the coil carrier 15 is provided with a ceramic boundary as disclosed within the present specification.

[0274] FIG. 3 is a schematic side view showing an appropriate change in the cross section of the coil disk 6. The left side of FIG. 3 shows a schematic drawing of the winding section 13 in which the thickness of the passive regions 17a and 17b is only half the thickness of the active region 16, with a ratio of 1:1. Within the same coil disk 6, only the passive regions 17a and 17b always partially overlap each other (they do not overlap entirely), and the active regions 16 never overlap each other. In the left side of FIG. 3, the thick active regions 16 are arranged side by side on the same plane, whereas the passive regions 17a and 17b are only half as thick due to the cross-sectional change and are also divided into different planes, so that the overall ratio between the active region 16 and the passive regions 17a and 17b is 1:1, i.e., the sum of the thicknesses of the passive regions 17a and 17b is completely equal to the thickness of the active region 16 in cross section.

[0275] The central drawing in FIG. 3 also shows a cross section of the coil disk 6 with a ratio of 1:1.5. As a result of the overlap, in cross section, the sum of the thicknesses of the passive areas 17 is exactly 1.5 times the thickness of the active area 16. This overlapping arrangement requires less installation space in side view. The two embodiments depicted under the letters "1:1.5" differ in terms of the planar displacement: in the first embodiment (left side), one space is created to the right of the active area 16, whereas in the second embodiment (right side), two spaces are created on both sides of the active area 16. The magnets of the magnetic structure enter the space thus created, so that the axial distance or gap between the active area 16 and the permanent magnets 5 can be reduced (although it cannot be completely eliminated). This allows for efficient use of the available installation space. As a variant, the created space can also be used for cooling.

[0276] Finally, the right diagram of FIG. 3 depicts a ratio of 1:0.7. The three embodiments in the figure show different forms of space resulting from appropriate changes in the cross section and plane of the passive areas 17a, 17b. Such space can also be used for cooling. In the embodiment described here, a flexible stranded wire made of copper or aluminum with a diameter of less than 2 mm (1.2 mm in the embodiment shown) is preferably used for the winding 13. The stranded wire is made up of a number of individual strands, each with a diameter of less than 0.2 mm (typically 0.05 mm in the embodiment shown), electrically insulated from one another.

[0277] The spaces between the active areas 16 configured as webs of the coil disks 6 forming the coil module 18 can be used for the flow of a cooling medium. For liquid-tightness, the coil disks 6 are covered on the side facing the magnet disk 4 with a fluid-tight membrane made of a non-conductive material. This seals the coil module 18, which is made up of a number of coil disks 6, from the outside. The shape of the spaces can be rectangular, triangular or trapezoidal, and can also be complicated in each case.

[0278] The diagram shown on the left side of Fig. 4 is a plan view of an arbitrary winding portion 13 corresponding to Fig. 2. As is clear from the cross-sectional view of the winding portion 13 shown on the right side of Fig. 4, the active region 16 is thicker than the passive regions 17a and 17b.

[0279] As in FIG. 2, circles K1 and K2 represent the extent of the active area 16.

[0280] Fig. 5 is a plan view of the coil module 18 corresponding to Fig. 2, in which two coil disks 6 are arranged one on top of the other in the axial direction. Each coil disk 6 is embedded in a coil carrier ring 20 attached to the coil carrier 15, and electrical contacts 19 from the windings 13 are drawn out to the coil carrier ring 20. In this embodiment, the coil carrier ring 20 is made of glass fiber-epoxy resin fabric.

[0281] 6 is a cross-sectional view of a coil module 18. Two coil disks 6 are arranged in combination such that a space 21 is formed between the active areas 16 of the two coil disks 6, forming a cooling channel as described in the context of this specification. The coil disks are sealed fluid-tight by a membrane, allowing the introduction of a cooling medium into this space 21.

[0282] 7 shows the inner side of a coil disk 6 of a coil module for an electric machine, on the basis of which a detailed description of the cooling geometry is given. The coil disk 5 comprises a coil carrier 15 made of an electrically insulating material and at least one winding 13 made of an electrically conductive material. The at least one winding 13 is arranged on or in the at least one coil disk 6 in a circumferential direction around a central portion 14 of the coil disk 6.

[0283] Advantageously, the windings 13 are as described in detail in the context of this specification and have an active area 16 and a passive area 17a, 17b, in which the active areas 16 of the different windings 13 do not overlap each other, whereas each passive area 17a, 17b of any winding 13 overlaps the corresponding passive areas 17a, 17b of the two immediately adjacent windings 13, respectively, and the axial thickness of the cross section of each winding 13 is greater in the active area 16 than in the passive area 17. However, the windings 13 may also be of another type. For example, at least one winding 13 may be configured in the form of at least one winding arranged in a meandering manner around a central portion 14.

[0284] The coil disk 6 further has a generally annular recess 22. The recess 22 is located on the inside of the coil disk 6, i.e., on the side of the coil module facing the other coil disk, and the cooling channel is formed by sandwiching the recess 22 inside the two coil disks. The recess 22 has an outer edge 24 and an inner edge 26, and is recessed from the outer edge 24 and the inner edge 26 relative to the remaining surface of the coil disk 6. That is, except for the recess 22, the inner surface of the coil disk 6 is located substantially in the same plane, and the edges 24, 26 respectively form a transition from the flat inner surface of the coil disk 6 to the recess 22. Although the recess 22 is depicted as a complete ring in this embodiment, it is not necessary for the present invention to be strictly annular. The recess 22 extends approximately around the center 14, but is not located in the center 14 itself. However, the recess 22 may have multiple webs that interrupt the recess 22, as described in detail elsewhere in this specification. Additionally, the inner edge 26 and / or the outer edge 24 of the recess 22 need not be strictly annular, but may be, for example, polygonal or irregular in shape.

[0285] The inner edge 26 of the recess 22 is located in the transition of the winding part 13 from the active area 16 to the inner passive area 17a. The outer edge 24 of the recess 22 is located in the radially outermost part of the outer passive area 17b of the winding part 13. Such an arrangement of the recess 22 can be advantageous not only because the radially inner passive area 17a is thicker than the radially outer passive area 17b due to space limitations, but also because the radially inner passive areas 17a of directly adjacent winding parts 13 overlap each other, unlike the active areas 16, so that the sum of the axial thicknesses of the inner passive areas 17a is greater than the thickness of the active area 16. Thus, space is provided for the recess 22 in the area of ​​the active area 16 and, optionally, in the area of ​​the outer passive area 17b. Alternatively, the outer edge 24 of the recess 22 may be located at the transition between the active area 16 and the radially outer passive area 17b.

[0286] The above arrangement of recesses 22 may be advantageous if the design of the electric machine is to be optimised as much as possible, however, other arrangements of recesses 22 are possible, for example, to make compromises with respect to space requirements and / or performance and / or efficiency.

[0287] 8A to 8D, there are various possible cross sections of the recess 22. Each of Fig. 8A to Fig. 8D is a cross-sectional view of the plane BB shown in Fig. 7.

[0288] Although not explicitly shown in the drawings, the coil disc 6 has a ceramic boundary, as described in the context of this patent specification, which separates the coil carrier 15 from the refrigerant flow passage formed by the recess 22 so that the material of the coil carrier 15 does not absorb the refrigerant (especially water-based refrigerants).

[0289] 8A depicts a rectangular cross-section recess 22. The recess 22 has an outer side 30, a bottom 28, and an inner side 32, the inner and outer sides 30, 32 being perpendicular to the bottom 28, which is parallel to the inner side of the coil disk. Thus, the recess 22 has a constant radial depth 34 from the inner side to the outer side, i.e., from the inner edge 26 to the outer edge 24.

[0290] In Fig. 8B, the recess 22 is depicted with a trapezoidal cross section. In contrast to the cross section shown in Fig. 8A, the side walls 30, 32 are not perpendicular to the bottom surface 28 but are inclined towards the bottom surface 28, so that the depth of the recess 22 always increases towards the bottom surface 28 in the region of the side walls 30, 32. In the region of the bottom surface 28, it may return to a constant height as described in connection with Fig. 8A.

[0291] FIG. 8C depicts the recess 22 with a depth 34a, 34b that increases radially from the inside to the outside, i.e., from the inner edge 26 to the outer edge 24. That is, the bottom surface 28 is not parallel to the inner surface of the coil disc, at least in part. For example, a part of the bottom surface 28 (e.g., a radially outer part of the bottom surface 28) can be parallel to the inner surface of the coil disc, while another part of the bottom surface 28 (e.g., a radially inner part of the bottom surface 28) can be inclined such that the depth 34a, 34b of the recess 22 increases from the radially inner to the radially outer side. Furthermore, the inner side surface 32 and the outer side surface 30 can be perpendicular to the inner surface of the coil disc or inclined relative to the inner surface. In this example, the outer side surface 30 is perpendicular to the inner surface of the coil disc, while the inner side surface 32 is inclined relative to the inner surface.

[0292] The recess 22 may be provided in the coil disk such that the portion of the bottom surface 28 parallel to the inner side surface of the coil disk is located in a portion of the radially outer passive region 17b of the winding that includes a radially extending region with a changing cross section. The inclined portion of the bottom surface 28 is located in a portion of the active region of the winding that flares outward. The inner side surface 32 is located in a region with a changing cross section of the inner passive region of the winding.

[0293] Such a cross section of the recess 22 shown in Figure 8C may be provided in particular when the active area of ​​the winding has a "flared" configuration as described in the present patent specification. Such a shape of the recess may also be called a "V-cooling" geometry.

[0294] Figure 8D illustrates a cross section of a recess 22 in which there is a continuous and / or continuous transition from the inner surface of the coil disk to the inner side 32, the bottom 28 and the outer side 30. Such continuous and / or continuous transitions are also possible in the cross sections shown in Figures 8A-8C.

[0295] The recesses depicted in Figures 8A-8D may comprise ceramic interfaces as disclosed as part of this specification.

[0296] Moreover, the recess 22 may have a cross-sectional shape obtained by combining the cross sections depicted in FIGS. 8A to 8D.

[0297] 9A and 9B are plan views of the winding 13 to explain in more detail the "flared" configuration disclosed in the context of the present patent specification. The winding has two radially extending active regions 16 and an inner tangentially extending passive region 17a and an outer tangentially extending passive region 17b that connect the two active regions 16, respectively. As disclosed in the context of the present patent specification, the axial thickness of the active region 16 of the winding 13 is greater than the axial thickness of the passive regions 17a, 17b. The passive regions 17a, 17b include short radial regions 35, 36 adjacent to the active region 16 where a change in cross section of each winding 13 occurs, which may also involve a displacement of the plane. Such transition regions may also be provided in the active region 16.

[0298] The active area 16 has a diverging geometric shape. That is, the tangential width of the winding 13 increases from the radially inner side to the radially outer side in the active area 16, i.e. the tangential width of the winding 13 reaches a minimum value 38 at the radially innermost point of the active area 16, which is in contact with the inner cross-sectional change 35, and a maximum value 40 at the radially outermost point of the active area 16, which is in contact with the outer cross-sectional change 36. The width of the winding at the cross-sectional changes 35, 36 can be within and / or outside these values. The axial thickness of the winding at the active area 16 decreases from the radially inner side to the radially outer side, i.e. the maximum value 42 at the radially innermost point of the active area 16, which is in contact with the inner cross-sectional change 35, and a minimum value 44 at the radially outermost point of the active area 16, which is in contact with the outer cross-sectional change 36. The thickness of the winding at the cross-sectional changes 35, 36 can be within and / or outside these values. The cross-sectional area of ​​the windings 13 in the active region 16 remains substantially constant along the radial direction.

[0299] This configuration of flared windings at the active area 16 may be advantageously used in conjunction with the recessed or "V-cooled" geometry depicted in Figure 8C, as depicted, for example, in Figure 10.

[0300] FIG. 10 is a cross-sectional view of a coil module 18. The coil module comprises first and second coil disks 6 each having a winding 13 with a flared geometric shape as shown in FIG. 9A and FIG. 9B. The first and second coil disks 6 each have a substantially annular recess 22 each extending from a cross-sectional change 35 inside the winding 13 to a passive area 17b outside the winding. Between the cross-sectional changes 35, 36, the depth of the recess 22 increases continuously from the radially inner side to the radially outer side. This gives the recess a so-called "V-cooled" geometric shape.

[0301] In this example, the first and second coil disks 6 each have a recess 22 that completely faces each other when the coil module 18 is assembled, thereby confining and forming the cooling flow passage 23.

[0302] 11A and 11B are plan views showing the inner side of the first coil disk 6a and the inner side of the second coil disk 6b, respectively, intended to be assembled into a coil module. In these figures, for the sake of clarity, the windings are not shown. The first coil disk 6a and the second coil disk 6b each have a substantially annular recess 22a, 22b. Furthermore, the recess 22a is formed with a web 38a, and the recess 22b is formed with a web 38b, the upper part of each of which is located flush with the rest of the inner side of the coil disk 6a, 6b (i.e., away from the recess 22a, 22b).

[0303] The first coil disk 6a further has an inlet hole 40a, an inlet passage 44, and an outlet hole 42a. The inlet passage 44 forms an inlet opening 43 in the side of the recess 22a. The second coil disk 6b has an inlet hole 40b, an outlet hole 42b, and an outlet passage 46. The outlet passage 46 forms an outlet opening 45 in the side of the recess 22b.

[0304] With this arrangement, after the coil module is assembled, the refrigerant can flow through the inlet holes 40a, 40b, the inlet flow path 44 and the inlet opening 43, as shown by the arrows, within the refrigerant flow path formed by the recesses 22a, 22b, and then flow from the outlet opening 45 to the outlet 46 and the outlet holes 42a, 42b.

[0305] In general, the electric machine is formed by connecting a plurality of coil modules as described above via coil spacers. The coil spacers have inlet holes and outlet holes corresponding to each other, and when assembled, all the inlet holes are aligned in a straight line and all the outlet holes are aligned in a straight line. In this case, the inlet holes and outlet holes may be omitted for the coil module and coil spacer located at one axial end of the electric machine. The coolant can be supplied and discharged through the inlet holes and outlet holes of the coil module and spacer located at the opposite axial end of the electric machine.

[0306] 12A, 12B and 12C show coil modules to illustrate the "flaring" of the active area and "V-cooling" as disclosed herein.

[0307] 12A is a perspective view of the coil module 18. The coil module includes a first coil disk 6a and a second coil disk 6b. The first coil disk 6a and the second coil disk 6b are attached to each other so that their inner surfaces face each other. As a result, two recesses 22a, 22b provided on the inner surfaces of the first coil disk 6a and the second coil disk 6b face each other or overlap each other, forming a cooling flow path 23 between the coil disks 6a, 6b.

[0308] The first coil disk 6a and the second coil disk 6b each have a number of windings 13. These windings 13 of each coil disk 6a, 6b may be of different design. The windings of the first group 13a are located in a first plane, both the active area 16a and the passive area being located in the first plane. The windings of the second group 13b are arranged such that the active area 16b is located in the first plane, while the tangential area is located in a second plane offset from the first plane. A planar displacement occurs at the transition to the active area 16b. The windings of the third group 13c are arranged such that the tangential area is located in both the first plane and the second plane, and a planar displacement occurs in the tangential area. In addition, a planar displacement occurs between the part of the tangential area located on the second plane and the active area 16c located on the first plane, so that the active areas 16a, 16b, and 16c of each coil disk 6a, 6b are entirely located on the first plane.

[0309] 12B is a top view of coil module 18. The windings have active area 16 and passive areas 17a, 17b as disclosed herein. It can be seen that active area 16 of windings 13 has a flared shape as described herein.

[0310] Also shown are windings 13a, 13b, and 13c as shown in Figure 12A. It can be clearly seen that adjacent active areas 16a, 16b, and 16c are substantially adjacent, and preferably, there are no gaps between them.

[0311] 12C is a perspective view of coil module 18 with some of the windings omitted, and clearly shows flow path 23 between first coil disk 6a and second coil disk 6b. That is, a space is formed between winding portion 13d of first coil disk 6a and winding portion 13e of the second coil disk, in which the axial height (or axial thickness) increases from the radially inner side to the radially outer side.

[0312] FIG. 13A is a perspective view of a coil module 18 according to an embodiment of the present invention. The coil module includes a first coil disk 6a and a second coil disk 6b. The first coil disk 6a includes a first coil carrier 15a and a first coil carrier ring 20a that surrounds the first coil carrier 15a radially outward. Similarly, the second coil disk 6b includes a second coil carrier 15b and a second coil carrier ring 20b that surrounds the second coil carrier radially outward. The first and second coil carriers 15a and 15b each have a winding 13 embedded therein, as disclosed in the context of this specification. The winding 13 includes an active region 16 that extends substantially in the radial direction, and inner and outer passive regions 17a and 17b that extend substantially in the tangential direction. The winding 13 is electrically connected to a contact 19.

[0313] FIG. 13B is a plan view of the coil carrier shown in FIG. 13A.

[0314] Fig. 13C is a cross-sectional view taken along the cutting plane AA shown in Fig. 13B. As shown in Fig. 13C, the first and second coil disks 6a, 6b are configured to form a substantially annular cooling passage 23 therebetween. In this embodiment, the cooling passage 23 extends in a radial portion of the coil disks 6a, 6b and the coil carriers 15a, 15b where the active region 16 and the outer passive region 17b of the winding portion 13 are located.

[0315] The coil module 18 further comprises first and second ceramic interfaces 56a, 56b as well as a radially inner ceramic interface 57 and a radially outer ceramic interface 58, which surround the cooling passage 23 and separate it from the first coil carrier 15a and the second coil carrier 15b.

[0316] Fig. 13D is a cross-sectional view along the cutting plane BB shown in Fig. 13B. Fig. 13D also shows the inlet opening 54 and the outlet opening 55. Fig. 13D further shows that the first and second ceramic interfaces 56a, 56b have openings 62 and 61 corresponding to the inlet opening 54 and the outlet opening 55, respectively. In this way, the coolant can enter the cooling channel 23 through the inlet opening 54, flow through the cooling channel 23 and exit through the outlet opening 55. Furthermore, the seals 56a, 56b, 57, 58 ensure that the coolant does not come into contact with the material of the coil carriers 15a, 15b.

[0317] Figure 14A shows a coil disk 6 as mounted in a coil module 18, for example as depicted in Figures 13A-13C. The coil disk 6 has a coil carrier 15 with a winding portion as disclosed in the context of this specification, and a coil carrier ring 20.

[0318] The coil carrier 15 has a radially inner region 50 and a radially outer region 51. The radially inner region 50 is undulating with respect to the radially outer region 51. In other words, the axial thickness of the radially inner region 50 is thicker than that of the radially outer region 51. The radially inner region 50 is a passive region of the winding part located in the radially inner region. The active region and the radially outer region of the winding part are located in the radially outer region 51. The coil carrier ring 20 is also undulating with respect to the radially outer region 51 of the coil carrier 15, and is at approximately the same height as the radially inner region 50 of the coil carrier 15. In a state after the first coil disk and the second coil disk are assembled, the radially inner region 50 of the first coil carrier 15 and the radially inner region 50 of the second coil carrier overlap each other.

[0319] As a result, when two coil disks 6 having mirror-symmetric structures are brought together, a cooling flow passage is formed in the area between the two coil disks, between the coil carrier ring 20 and the radially inner area 50 of the coil carrier 15.

[0320] The coil carrier ring 20 further has an inlet opening 54 and an outlet opening 55. The coil carrier ring 20 has a recessed area 52 around the inlet opening 54 that meets the radially outer area 51 of the coil carrier 15 at approximately the same height as the radially outer area 51. The coil carrier ring 20 has a recessed area 53 around the outlet opening 55 that meets the radially outer area 51 of the coil carrier 15 at approximately the same height as the radially outer area 51.

[0321] The coil disc 6 in FIG. 14A is depicted without a ceramic boundary.

[0322] 14B shows the coil disc 6 depicted in FIG. 14A with a ceramic interface 56. The ceramic interface 56 is substantially in the form of an annular disc located in the radially outer region 51 and in the recessed regions 52, 53 of the coil carrier ring. In other words, the substantially annular ceramic disc 56 has two protrusions 59, 60 corresponding to the recessed regions 52, 53 of the coil carrier ring 20.

[0323] 14B further illustrates that the coil disk 6 includes a radially inner boundary 57 that surrounds the radially inner edge of the annular ceramic disk 56. The coil disk 6 further includes a radially outer boundary 58 that surrounds the radially outer edge of the annular ceramic disk 56.

[0324] The annular ceramic disc 56 further has two openings 61 , 62 corresponding to the inlet opening 54 and the outlet opening 55 .

[0325] In this way, the cooling passages are completely separated from the surrounding material of the coil carrier 15 and the coil carrier ring 20.

[0326] For example, coil disk 6 is a first coil disk and ceramic boundary 56 is a first coil disk. The coil module disclosed as part of this specification further includes a second coil disk that is generally a mirror image of coil disk 6, and a second ceramic boundary.

[0327] 15A shows a first or second ceramic interface 56. The ceramic interface 56 includes a number of connecting elements 53 oriented perpendicular to the ceramic interface 56. In a coil module with two ceramic interfaces 56, a connecting element 53 connects the first and second ceramic interfaces.

[0328] 15B shows a first or second ceramic interface 56 with a connecting element 64 configured in the form of a guiding structure or rib, which connects the first and second ceramic interfaces 56 in the coil module having two ceramic interfaces 56.

[0329] 16 shows the ceramic interface 56. The ceramic interface 56 has a number of protrusions 65 in the form of a "slice of pie" or sector shape that are configured to protrude into corresponding gaps formed between two adjacent active areas of the windings in the coil carrier.

[0330] FIG. 17 illustrates a vehicle 150 including an electric machine 152 as disclosed herein.

[0331] FIG. 18 shows a machine tool 154 that includes an electric machine 156 as disclosed in the context of this specification.

[0332] The configurations of the respective embodiments disclosed only in the examples may be used in combination or may be separately described in the claims.

Claims

1. A coil module (18) for an electric machine, comprising: a first coil disk (6, 6a) having a first coil carrier (15, 15a) made of an electrically insulating material, at least one winding portion (13) made of an electrically conductive material embedded in the first coil carrier (15, 15a), and a first ceramic boundary portion (56, 56a); a second coil disk (6, 6b) having a second coil carrier (15, 15b) made of an electrically insulating material, at least one winding portion (13) made of an electrically conductive material embedded in the second coil carrier (15, 15b), and a second ceramic boundary portion (56, 56b); Equipped with the first coil disk (6, 6a) and the second coil disk (6b) are attached to each other in such a manner that a substantially annular cooling passage (23) for a coolant is formed between the first coil disk (6, 6a) and the second coil disk (6b); the first ceramic boundary (56, 56a) and the second ceramic boundary (56, 56b) each at least partially form an inner wall of the generally annular cooling channel (23); The first coil carrier (15, 15a) and / or the second coil carrier (15, 15b) has a substantially annular recess, the first ceramic interface (56, 56a) and / or the second ceramic interface (56, 56b) are provided in the form of a substantially annular ceramic disk disposed within the substantially annular recess of the first coil carrier and / or the second coil carrier. A coil module (18).

2. 2. The coil module (18) of claim 1, wherein the first and / or second ceramic boundaries (56, 56a, 56b) are made of aluminum-based and / or silicon-based ceramics, preferably made of a material selected from the group consisting of aluminum oxide, aluminum nitride, silicon carbide and silicon nitride.

3. 2. The coil module (18) of claim 1, wherein the first ceramic boundary (56, 56a) forms an inner wall of the generally annular cooling passage (23) over the entire radial area of ​​the generally annular cooling passage; and / or The coil module (18), wherein the second ceramic boundary (56, 56b) forms an inner wall of the generally annular cooling passage (23) over an entire radial area of ​​the generally annular cooling passage.

4. 2. The coil module (18) of claim 1, wherein the first ceramic interface (56, 56a) comprises a first ceramic disk disposed on the first coil carrier (15, 15a) and / or the second ceramic interface (56, 56b) comprises a second ceramic disk disposed on the second coil carrier (15, 15b), Preferably, the first ceramic disc (56, 56a) and / or the second ceramic disc (56, 56b) of the coil module (18) has a thickness of 0.1 mm to 1 mm, preferably 0.2 mm to 0.8 mm, more preferably 0.35 mm to 0.7 mm.

5. 2. The coil module (18) of claim 1, wherein the first ceramic interface (56, 56a) comprises a ceramic coating applied to the first coil carrier (15, 15a) and / or the second ceramic interface (56, 56b) comprises a second ceramic coating applied to the second coil carrier (15, 15b), The coil module (18), wherein the first ceramic coating and / or the second ceramic coating has a thickness of 1 μm to 100 μm, preferably 1 μm to 50 μm, and more preferably 1 μm to 30 μm.

6. The coil module (18) of claim 1, further comprising: at least one connecting element (63, 64) disposed within the substantially annular cooling channel (23) and connected to both the first ceramic boundary (56, 56a) and the second ceramic boundary (56, 56b), preferably integrally formed therewith; Equipped with Preferably, said at least one connecting element (63, 64) comprises: It comprises an aluminium-based and / or silicon-based ceramic, preferably made of a material selected from the group consisting of aluminium oxide, aluminium nitride, silicon carbide and silicon nitride, and / or Preferably, it is bonded to the first ceramic boundary and / or the second ceramic boundary or is integrally formed to the first ceramic boundary and / or the second ceramic boundary, and / or struts, preferably arranged perpendicular to said first and / or second coil discs (6, 6a, 6b); and / or A coil module (18) including ribs extending parallel to said first and / or second coil discs (6, 6a, 6b).

7. The coil module (18) of claim 1, further comprising: a radially inner ceramic boundary (57) and a radially outer ceramic boundary; Equipped with Preferably, the radially inner ceramic boundary (57) is flange-shaped and / or ring-shaped and is disposed radially inside and adjacent to the first ceramic boundary (56, 56a) and the second ceramic boundary (56, 56b), Preferably, the radially outer ceramic boundary portion (58) is flange-shaped and / or ring-shaped and is disposed radially adjacent to the outside of the first ceramic boundary portion (56, 56a) and the second ceramic boundary portion (56, 56b).

8. 2. The coil module (18) according to claim 1, wherein the first coil disk (6, 6a) and / or the second coil disk (6, 6b) have inlet openings (43, 54) for introducing a coolant into the substantially annular cooling channel (23); and / or The first coil disk (6, 6a) and / or the second coil disk (6, 6b) have an outlet opening (45, 55) for directing coolant out of the substantially annular cooling channel (23).

9. 2. The coil module (18) according to claim 1, wherein a plurality of winding portions (13) made of a conductive material are embedded in the first coil carrier (15, 15a), and each of the winding portions (13) is embedded in the first coil carrier (15, 15a) in a circumferential direction around a center portion (14) of the first coil carrier (15, 15a); A plurality of winding portions (13) made of a conductive material are embedded in the second coil carrier (15, 15b), and the winding portions (13) are embedded in the second coil carrier (15, 15b) in a circumferential direction around a center portion (14) of the second coil carrier (15, 15b); Each of the windings (13) has two active regions (16) extending radially from the central portion (14) and two passive regions (17b) extending tangentially at the radially outer and inner edges, In a plan view of the coil disk (6, 6a, 6b), the active regions (16) of different winding sections (13) do not overlap each other, whereas each passive region (17a, 17b) of any one of the winding sections (13) partially overlaps the corresponding passive regions (17a, 17b) of two immediately adjacent winding sections (13), and the axial thickness of the cross section of each of the winding sections (13) is greater in the active region (16) than in the passive regions (17a, 17b).

10. 10. The coil module (18) according to claim 9, wherein adjacent active areas (16) of each of the plurality of winding portions (13) of the first coil disk (6, 6a) and the second coil disk (6, 6b) are spaced apart from each other in a tangential direction such that a gap is located between the adjacent active areas (16); The first ceramic boundary (56, 56a) and the second ceramic boundary (56, 56b) each have a protrusion (65) that extends into the gap located between the adjacent active regions (16).

11. A coil module (18) as described in claim 9, wherein the cooling passage (23) is located at least in the region of the radially extending active region (16), and preferably also in the region of the radially outer passive region (17b).

12. 10. The coil module (18) according to claim 9, wherein the winding portion is configured of a thin stranded wire of a plurality of wires, each wire having a wire diameter of 0.1 mm or less, that are electrically insulated from one another.

13. A bearing structure (1, 3), A shaft (2) guided by the bearing structure (1, 3); and arranged coaxially along the shaft (2) are at least one magnet module (4) consisting of a plurality of permanent magnets (5) and at least one coil module (18) according to any one of claims 1 to 12.

14. A vehicle (150) or a machine tool (154) comprising an electric machine according to claim 13.

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