Coil component for an automotive electrical machine and method for manufacturing the coil component

Abstract

The present invention relates to a coil component (10) for an automotive electric machine, the coil component (10) comprising a support body (12) having a plurality of axially extending slots (14) spaced apart in a circumferential direction (U) of the support body (12), a plurality of hairpin bodies (16) at least partially disposed within the slots (14), and at least one insulating member disposed in one of the slots (14), which electrically insulates the hairpin body (16) disposed in the slot (14) from a slot wall of the support body (12) that defines the slot (14). The insulating members (18, 30, 36) are supported against the slot wall of the support body (12) via a wedge-shaped portion (28), thereby converting a force acting on the wedge-shaped portion (28) in the axial direction (A) into a force acting in the circumferential direction (U), which presses the insulating members (18, 30, 36) against the hairpin body (16) in the circumferential direction (U). Regarding coil components.

Description

[Technical Field]

[0001] The present invention relates to a coil component for an automotive electric machine and to a method for manufacturing a coil component for an automotive electric machine. [Background technology]

[0002] Patent Document 1 discloses a coil component for an electric machine, comprising a holder and a coil winding accommodated at least in sections within the holder. The holder has an annular portion with a plurality of circumferentially spaced slots, each of which accommodates a plurality of winding sections of the coil winding. In at least one slot, an insulating sheet is disposed between the holder and the plurality of winding sections, the insulating sheet having two extensions that project beyond the winding sections toward the radial opening of the at least one slot. In at least one slot fitted with the insulating sheet, a closing element is accommodated within the holder facing the radial opening, the two extensions being shaped and arranged such that the closing element is separated from the holder by the extensions.

[0003] It is already known that stator slots are insulated with a surface insulating material. After the windings are installed, they are impregnated with a synthetic resin to secure them in the stator, improve heat transfer to the laminated core, and increase partial discharge resistance. However, the varnish insulation of the stator windings is incompatible with this impregnation resin. During trickle impregnation, the impregnation resin can reach the stator winding heads, potentially compromising the functionality of the winding varnish insulation at that point. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] International Publication No. 2022 / 033627 Summary of the Invention [Problem to be solved by the invention]

[0005] The object of the invention is to provide a solution that allows the coil of a coil element to be electrically insulated particularly well from the carrier, and prevents the insulating function of the coil varnish from being impaired. [Means for solving the problem]

[0006] This problem is solved according to the present invention by the subject matter of the independent patent claims. Further possible embodiments of the invention are disclosed in the subclaims, the description and the drawings. Features, advantages and possible embodiments described in the description for one of the subject matters of an independent claim can at least equally be regarded as features, advantages and possible embodiments of each of the subject matters of the other independent claims and of the combinable subject matters of these independent claims, if necessary, in relation to one or more subclaims.

[0007] The present invention relates to a coil component for an electric machine of an automobile. The coil component may be a rotor or a stator of the electric machine. The electric machine is, in particular, a traction machine capable of electrically driving an automobile. The coil component has a support body with a plurality of slots arranged circumferentially and extending in the axial direction. The support body may, for example, have a laminated core made of a plurality of plates stacked one on top of the other in a stacking direction, or may be manufactured in one piece, for example, by a sintering process. The coil component further has a plurality of hairpin elements at least partially arranged in the slots. These hairpin elements are sometimes called plug-in coils. These hairpin elements may be varnished flat copper wires bent into a U-shape and inserted into the slots of the support body. Alternatively, the hairpin elements may be formed as I-shaped pins, thereby forming straight flat copper pieces. The plurality of hairpin elements of the coil component together form the coil of the coil component. This means that the coil includes all of the hairpin elements of the coil component, and these hairpin elements are inserted into the slots of the support body. In particular, at least one hairpin body is arranged in each slot of the holder, and in particular, a plurality of hairpin bodies are arranged in each slot of the holder.

[0008] The coil assembly includes at least one insulating element arranged in one of the slots, electrically insulating the hairpin element arranged in the slot from the slot wall of the holder that defines the slot. In particular, the coil assembly includes a plurality of insulating elements, with at least one insulating element arranged in each slot of the holder, insulating the hairpin element arranged in the slot from the slot wall of the holder that defines the slot. To ensure particularly good heat transfer from the hairpin element to the holder, the insulating element is supported against the slot wall of the holder via a wedge-shaped portion. A force acting on the wedge-shaped portion in the axial direction of the holder is converted into a force acting in the circumferential direction of the holder via the wedge-shaped portion, which presses the insulating element against the hairpin element in the circumferential direction. The axial direction of the holder corresponds in particular to the rotation axis of the rotor or the central axis of the stator as the coil assembly. The circumferential direction corresponds to the direction of rotation of the rotor relative to the stator in the electric machine. The wedge-shaped portion thus clamps the at least one insulating element in the slot, so that the at least one insulating element rests or rests on the hairpin body quite closely and particularly evenly. This allows for particularly good heat transfer from the hairpin body via the insulating element to the holder. This excellent heat transfer allows particularly good cooling of the hairpin body, which in turn makes it particularly easy to prevent the hairpin body from overheating. As a result, the electric machine can be operated particularly efficiently and with very high power.

[0009] In one possible embodiment of the present invention, the insulating element has a wedge-shaped portion such that two side surfaces of the insulating element meet at an acute angle. In other words, the wedge-shaped portion of the insulating element has a first surface and a second surface oriented obliquely thereto, which approach each other along the axial direction and in particular abut each other at their pointed edges. By providing the wedge-shaped portion in the insulating element itself, the number of components of the coil element required to electrically insulate the hairpin body from the holder and, on the other hand, to place the insulating element quite closely against the hairpin body, is significantly reduced. This makes the coil element particularly easy to manufacture.

[0010] In a possible development of the invention, the insulating element has a U-shaped cross section. The U-shape of the cross section is present when the insulating element is axially inserted into the slot of the holder, in particular when a cross section through the insulating element is perpendicular to the axial direction. This U-shaped cross section of the insulating element allows at least one of the hairpins arranged in this slot, in particular all of the hairpins arranged in this slot, to be electrically insulated on at least three sides by using the insulating element. This allows the hairpins to be electrically insulated from the holder over a particularly large surface by using the insulating element.

[0011] In yet another possible embodiment of the invention, a plurality of insulating elements are arranged axially one above the other in one slot and are partially nested so that the respective wedge-shaped portions of the insulating elements abut one another in the same slot, and the insulating elements are clamped together in the slot via the matching wedge-shaped portions of the insulating elements arranged in the common slot, so that one insulating element presses another insulating element in the same slot particularly firmly against the hairpin body arranged in the slot.

[0012] In this regard, two insulating members may be provided in the slot, with the legs of their U-shaped cross sections facing each other, so that together they enclose an axially extending channel through which the hairpin extends. This means that by inserting multiple hairpins into a channel whose longitudinal direction extends in the axial direction of the holder, the multiple hairpins arranged in one common slot are reliably electrically insulated from the holder by both insulating members. In other words, the open sides of the U-shaped cross sections of the insulating members are oriented facing each other, so that the legs and backs of the insulating members together define a channel on the peripheral side.

[0013] In yet another possible embodiment of the present invention, the insulating element may have at least one straight section with a constant wall thickness extending in the axial direction and at least one wedge-shaped section axially adjacent to the straight section. For example, when inserted into the slot, the insulating element may have a central straight section, a wedge-shaped section axially adjacent to the straight section above, and another wedge-shaped section axially adjacent to the straight section below. This allows the insulating element to be wedged with the other insulating elements both axially above and axially below. Thus, multiple insulating elements may be axially arranged one above the other in the slot and wedged with each other by their respective wedge-shaped sections. This allows the individual insulating elements to be particularly easily injection-molded, since they can be manufactured particularly easily and with particularly consistent lengths by injection molding. It is only necessary to arrange multiple insulating elements axially one above the other until the hairpins arranged in the slot are insulated from the holder by each insulating element over the entire length of the slot. This makes it possible to produce particularly stable insulating elements in a particularly easy manner, while on the other hand it makes it possible to insulate the hairpin body particularly reliably from the holder.

[0014] In yet another possible embodiment of the present invention, at least one insulating element has an abutment that can abut against one end face of the holder and defines the axial end position of the insulating element. When the coil component has multiple insulating elements, at least one or at most two of these insulating elements can have this abutment, with the abutment of a first insulating element abutting against the first end face of the holder and the abutment of a second insulating element abutting against the second end face of the holder opposite the first end face. When the abutment of the insulating element abuts against the end face of the holder, it ensures that the hairpin element is completely electrically insulated from the holder up to the end face of the slot in which the insulating element is placed. This ensures that the hairpin element placed in the slot is completely electrically insulated from the holder up to the end of the slot and that, as a result of the insulating element not sliding into the slot, no electrical contact occurs between the hairpin element and the holder at the outer edge of the slot.

[0015] In a possible development of the invention, the insulating element is pressed onto the hairpin body by a slot insulating wedge with a wedge-shaped portion and separate from the insulating element. This means that the insulating element does not have a wedge-shaped portion. For example, the insulating element can be a slot insulating paper. This slot insulating paper can have a constant thickness over its entire axial height. Using the slot insulating wedge with a wedge-shaped portion, the slot insulating paper can be pressed onto the hairpin body. For this purpose, the slot insulating wedge is inserted and clamped between the holder and the insulating element, so that the insulating element directly abuts, and in particular is pressed against, the surface of the hairpin body. Therefore, the slot insulating paper makes it particularly easy to achieve the required insulation of the hairpin body, and the at least one slot insulating wedge ensures that the slot insulating paper abuts over a wide surface on the hairpin body and fills the gap between the slot insulating paper and the holder. As a result, it is not necessary to fill the gap between the slot insulating paper and the holder with impregnating resin.

[0016] The retainer may be provided with a guide bevel to facilitate the introduction of the wedge-shaped body between the retainer and the hairpin body.

[0017] The present invention relates to a method for manufacturing a coil component for an electric machine of an automobile. The electric machine includes a holder having a plurality of axially extending slots spaced apart around the holder. The coil component may be, for example, a rotor or a stator of the electric machine. This method particularly manufactures a coil component as described above in connection with the coil component according to the invention. In this method, a plurality of hairpin bodies and at least one insulating element are at least partially disposed in the slots, and the at least one insulating element electrically insulates the hairpin bodies from slot walls of the holder that define the slots. In particular, the method includes inserting a plurality of hairpin bodies and at least one insulating element into each of the slots of the holder. Furthermore, in this method, the at least one insulating element is supported against the slot walls of the holder via wedge-shaped elements, thereby converting an axial force acting on the wedge-shaped elements into a circumferential force that presses the insulating element against the hairpin body in the circumferential direction. Pressing the insulating element against the hairpin body results in a particularly large contact area between the hairpin body and the insulating element, which allows for particularly efficient heat transfer from the hairpin body to the holder via the insulating element. This allows for particularly efficient cooling of the hairpin body. The insulating element can be pressed against the hairpin body by providing a wedge-shaped portion on the insulating element, or by providing an additional slot insulating wedge with a wedge-shaped portion in the slot without providing a wedge-shaped portion on the insulating element. This method makes it possible to avoid using an impregnating resin to electrically insulate the hairpin body from the holder. As a result, the risk of the impregnating resin coming into contact with the varnish insulation and causing the varnish insulation of the coil to fail is eliminated. This significantly extends the service life of the coil component.

[0018] The coil element or method according to the invention does not use an impregnating resin, but instead uses a multi-part plastic slot insulator with wedge-shaped vertical wall sections that are inserted in a telescopic manner to clamp and fix the hairpin body within the holder, in particular within the laminated core.

[0019] Further features of the invention will become apparent from the claims, the drawings and the description of the drawings. The features and combinations of features mentioned above in the specification and shown below only in the description of and / or in the drawings can be used not only in the respective combinations described, but also in other combinations or alone, without departing from the scope of the invention. [Brief explanation of the drawings]

[0020] [Figure 1] 1 is a schematic cross-sectional view of a portion of a coil component for an electric machine in a first embodiment; [Figure 2] 2 is an exploded view of a hairpin body disposed in a slot of a holder of an electric machine according to the embodiment of FIG. 1, as well as two insulating members disposed in this slot; [Figure 3] FIG. 2 is a schematic perspective view of a portion of the coil component according to the first embodiment. [Figure 4] FIG. 10 is a schematic cross-sectional view of a portion of a coil component according to a second embodiment. [Figure 5] FIG. 10 is an exploded view of a portion of the coil component of the second embodiment; [Figure 6] FIG. 10 is a schematic cross-sectional view of a portion of a coil component according to a third embodiment. [Figure 7] FIG. 10 is an exploded view of a portion of a coil component according to a third embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0021] In these figures, elements that are identical and functionally equivalent are given the same reference numerals.

[0022] The figure shows a coil assembly 10 for an electric machine of an automobile. This electric machine is in particular an automotive traction machine that can drive a motor vehicle with electrical energy. Here, the coil assembly 10 is a stator of the electric machine. In particular, the stator is a hairpin stator.

[0023] The hairpin stator includes a support body 12 formed as a laminated core. The support body 12 has a plurality of slots 14 arranged in a circumferential direction U of the support body 12, with the longitudinal direction of the slots extending along the axial direction A of the support body 12. The coil component 10 further includes a plurality of hairpin bodies 16, which are wires for each phase (phase wires), inserted into the slots 14 of the support body 12. The entirety of the hairpin bodies 16 forms a coil. Each hairpin body 16 extends over the entire length of its associated (corresponding) slot 14 extending in the axial direction A. Here, the hairpin bodies 16 are arranged next to each other in each slot 14. Here, the hairpin bodies 16 are arranged in a row in order in the radial direction R of the support body 12. The radial direction R is perpendicular to the axial direction A. In order to electrically insulate the hairpin body 16 arranged in the slot 14 of the holder 12 from the holder 12, at least one insulating member or multiple insulating members are provided for each slot 14, and these are used to electrically insulate the hairpin body 16 from the holder 12.

[0024] 1, 2, and 3 show a coil component 10 according to a first embodiment, FIGS. 4 and 5 show a coil component 10 according to a second embodiment, and FIGS. 6 and 7 show a coil component 10 according to a third embodiment. These embodiments differ, inter alia, in the design of the respective insulating members. Common to all embodiments is that each insulating member is fastened to the holder 12 via at least one wedge-shaped portion, thereby allowing the insulating member to rest particularly closely and over a particularly large surface on the hairpin body 16. This allows particularly good heat transfer from the hairpin body 16 to the respective insulating member, and as a result, the hairpin body 16 can also be particularly well cooled during operation. All the embodiments have in common that at least one insulating member is disposed in each slot 14, and the insulating member electrically insulates the hairpin body 16 disposed in the slot 14 from the slot wall of the holder 12 that defines the slot 14, and the insulating member is supported against the slot wall of the holder 12 via the wedge-shaped portion. As a result, the force acting on the wedge-shaped portion in the axial direction A is at least partially converted into a force acting in the circumferential direction U, and this force presses the insulating member against the hairpin body 16 in the circumferential direction U. This pressing action acting in the circumferential direction can compensate for tolerances.

[0025] 1 to 5 have in common that at least one insulating member has a wedge-shaped portion. In a third embodiment of the present invention shown in Figures 6 and 7, the insulating member does not have a wedge-shaped portion. Instead, at least one slot insulating wedge 38 having a wedge-shaped portion and formed separately from the insulating member is provided in each slot 14, and this slot insulating wedge presses the insulating member against the hairpin body 16.

[0026] In a first embodiment of the coil component 10 shown in FIGS. 1 to 3, the coil component 10 includes two first insulating members 18. Each first insulating member 18 has a U-shaped cross section extending perpendicular to the axial direction A. As can be seen particularly clearly in FIG. 3, the two first insulating members 18 are oriented in the slot 14 in which the first insulating members 18 are disposed, with the legs of their U-shaped cross sections facing each other. Together, the first insulating members 18 surround a channel 20 extending in the axial direction A within the slot 14. All corresponding hairpin bodies 16 associated with the slot 14 are disposed in this channel 20. As a result, the hairpin bodies 16 disposed in the channel 20 are completely electrically insulated from the slot walls of the holder 12 that define the slot 14 by both first insulating members 18. This particularly reliably prevents conductive contact between the hairpin bodies 16 and the holder 12.

[0027] As can be seen particularly clearly in FIG. 1 , the first insulating member 18 includes a collar 22 at one end thereof, which provides an abutment 24. The collar 22 rests on a first end face 26 of the holder 12, causing the abutment 24 to abut against the first end face 26 of the holder 12. The abutment 24 against the first end face 26 of the holder 12 defines the axial end position of the first insulating member 18 within the slot 14. FIG. 2 shows that both first insulating members 18 of the first embodiment include a collar 22 with an abutment 24. The collar 22 of another first insulating member 18 rests on a second end face (not shown) of the holder 12 opposite the first end face 26, causing the abutment 24 of the other first insulating member 18 to abut against this second end face, thereby defining the axial end position of the other first insulating member 18 as well. This defined end position of the first insulating element 18, i.e., by resting the collars 22 of the first insulating element 18 on the opposite end faces of the carrier 12, ensures that the hairpin body 16 in each slot 14 is insulated from the carrier 12 by the first insulating element 18 along the entire length of the slot 14 in the axial direction A through the channels 20 formed by the first insulating element 18. As a result, the risk of electrical current passing between the hairpin body 16 and the carrier 12 is particularly low.

[0028] To ensure that at least one of the first insulating members 18 fits flatly onto the hairpin body 16 and eliminate or reduce gaps between the hairpin body 16 and the slot walls of the holder 12 that define the slot 14, the first insulating members 18 each have a wedge-shaped portion 28. As can be seen in FIG. 1 , the upper first insulating member 18 in the axial direction A has a wedge-shaped inner contour, while the lower first insulating member 18 in the axial direction A has a wedge-shaped outer contour. The wedge-shaped inner contour of the upper first insulating member 18 abuts on the wedge-shaped outer contour of the lower first insulating member 18. When a force acts on one of the first insulating members 18 toward the other first insulating member 18 in the axial direction A, the wedge-shaped portions of the first insulating members 18 move along each other. As a result, due to the principle of the inclined surface, the force acting in the axial direction A is converted by the wedge-shaped portions into a force acting at least partially in the circumferential direction, which presses the first insulating elements 18 not only against each other but also against the slot walls and against the hairpin body 16. As a result, the gap in the slot 14 filled with the hairpin body 16 can be reduced or, in particular, eliminated altogether. This allows for particularly good heat transfer from the hairpin body 16 to the carrier body 12.

[0029] Thus, in the first embodiment, two first insulating elements 18 are used, each in the form of a U-shaped sleeve with a wedge-shaped portion on the surface of the inner or outer profile. The wedge-shaped portion converts the axial force into a tangential force. When assembled in the axial end position, this results in a surface pressure between the wedge-shaped portion of the first insulating element 18 and the holding body 12, which is particularly configured as a laminated core, and the phase wire and thus the hairpin element 16. In each first insulating element 18, the wedge-shaped portion can be implemented by tapering the wall thickness along the axial path A and, if necessary, also in the radial direction R. As a result, the first insulating element 18 can be wedged in the circumferential direction U. The insulating elements of the first and second embodiments are made of electrically insulating plastic in this example.

[0030] In the first embodiment, to assemble the coil component 10, a sleeve-shaped first insulating member 18 is inserted into the slot 14 of the holder 12 in the axial direction A. The tangential dimension between the sleeve and the phase wires can be adjusted depending on the axial position of the sleeve. When assembled to the terminal position, a surface pressure is generated between the wedge-shaped portion of the first insulating member 18, the laminated core, and the phase wires, resulting in a large tangential force. The coil component 10 of the first embodiment is disassembled, can be manufactured in a short period of time, does not contain impregnating resin, has a high degree of slot filling, and allows the phase wires to be positioned in the center of the slot 14.

[0031] In the second embodiment shown in FIGS. 4 and 5, at least one first insulating member 18 and at least one second insulating member 30 are disposed within the slot 14. The first insulating member 18 includes a collar 22 that provides an abutment 24, thereby defining the axial end position of the first insulating member 18. The second insulating member 30 includes a straight portion 32 extending in the axial direction A and two wedge portions 34 that connect to the straight portion 32 above and below the axial direction A, respectively. The wedge portions 34 have a wedge shape. In a cross section of the second insulating member 30 extending perpendicular to the axial direction A, the second insulating member 30 has a U-shaped cross section. Here, when the second insulating member 30 is inserted into the slot 14, the legs of the U-shaped cross section are oriented radially in the same direction as the legs of the U-shaped cross section of the first insulating member 18. This means that the U-shaped cross sections of the first insulating member 18 and the second insulating member 30 have their openings facing in the same direction. In a longitudinal section extending in an axial direction A perpendicular to the radial direction R across one leg of the U-shaped cross section of the second insulating member 30, this longitudinal section has a trapezoidal shape with opposite sides oriented parallel to each other. This means that, in this example, the second insulating member 30 has a constant wall thickness in the straight section 32, but the wall thickness of the second insulating member 30 tapers toward each end (in this example, toward the upper end in the axial direction A and the lower end in the axial direction A) at the wedge-shaped section 34.

[0032] In the second embodiment, multiple second insulating members 30 can be arranged one above the other in the axial direction A in each slot 14, ensuring that the hairpin body 16 is electrically insulated from the holder 12 by each insulating member over the entire length of the slot 14 extending in the axial direction A. For example, a first insulating member 18 can be arranged at the top of the slot 14 in the axial direction, followed by one or more second insulating members 30 lined up in the axial direction A and another first insulating member 18 arranged axially below. The insulating members arranged one above the other in the axial direction A are in contact with each other via their wedge-shaped portions, which allows the insulating members to press against each other when an axial force is applied using the principle of an inclined surface, and the insulating members can press against the phase lines formed as the hairpin body 16 and the slot walls that define the slot 14. The embodiment of the insulation in the slot 14 by a plurality of second insulating elements 30 makes it possible to particularly easily injection-mold these second insulating elements 30 and the at least one first insulating element 18, since the length of each insulating element extending in the axial direction A can be adapted to the injection-mold process. This means that the length of the insulating elements is selected so that the insulating elements can be particularly easily manufactured in an injection-mold process. This results in a particularly easy manufacture of each insulating element and in particular a high stability of the insulating elements.

[0033] Thus, in the second embodiment of the coil component 10, trapezoidal slot insulators are used as the second insulating members 30, inclined toward each end face of the holder 12, in particular toward each end face of the laminated core. U-shaped sleeves with wedge shapes can be arranged on each end face of the holder 12, and in this example, these are shaped similarly to the first insulating members 18 described in relation to the first embodiment. In the second embodiment, when assembled at the axial end positions, a surface pressure is generated between the wedge-shaped portions of the slot insulators and the phase wires.

[0034] The second embodiment makes it possible to adjust the tangential dimension between the phase wires at the end faces and the slot wedges depending on the axial position of the slot wedges. The pressing force from the face results in a particularly high tangential force. Since no slot insulation paper is used in this second embodiment, there is no risk of the slot insulation paper popping out. The coil component 10 of the second embodiment is particularly easy to disassemble, does not contain impregnating resin, can be manufactured in a particularly short time, has a very high degree of slot filling, and allows the phase wires to be positioned in the center of each slot 14.

[0035] 6 and 7 show a third embodiment of the coil component 10. In this embodiment, each hairpin 16 is insulated from the respective slot walls of the holder 12 defining the associated slot 14 via slot insulating paper 36 as an insulating member. The slot insulating paper 36 extends over the entire height of the slot 14 in the axial direction A, thereby insulating the hairpin 16 disposed in the slot 14 from the holder 12 over the entire height of the slot 14. In this example, the slot insulating paper 36 has a constant wall thickness over its entire length. To ensure that the slot insulating paper 36 is in particularly firm contact with each hairpin 16 to ensure particularly good heat transfer, slot insulating wedges 38 with wedge shapes are provided. The slot insulating wedges 38 are inserted into each slot 14 between the slot insulating paper 36 and the walls defining the slot 14. This means that the slot insulating wedge 38 contacts both the slot wall portion defining the slot 14 and the slot insulating paper 36. The sides of the slot insulating wedge 38 that contact the slot insulating paper 36 and the slot wall portion intersect at an acute angle in the axial direction A. In this case, the leading edges of the slot insulating wedge 38 are each directed toward the center of the holder 12 in the axial direction A. When the slot insulating wedge 38 is inserted into the slot 14, the slot insulating paper 36 is pressed against the hairpin body 16 in the circumferential direction U. In this example, at least two slot insulating papers 36 are arranged in each slot 14, one on each side of the hairpin body 16 in the circumferential direction U. Therefore, the hairpin body 16 is electrically insulated from the holder 12 by the slot insulating papers 36 on its sides that are opposite each other in the circumferential direction U.

[0036] In the third embodiment, two slot insulating wedges 38 are thus provided for each slot 14 and for each end face of the holder 12. The two slot insulating wedges 38 for each end face press the slot insulating paper 36, which serves as a third insulating member, against the phase wires of the coil device 10. The axial force exerted when clamping the slot insulating wedges 38 is converted into a tangential force acting in the circumferential direction U. To facilitate the introduction of the slot insulating wedges 38 into each slot 14, the slot 14 may be provided with guide bevels 40 for each slot insulating wedge 38 on each end face of the holder 12.

[0037] Depending on the axial position of the slot insulating wedge 38, the tangential dimension between the slot insulating wedge 38 and the phase wires at each end face of the holder 12 can be adjusted. This creates a surface pressure between the slot insulating wedge 38 and the holder 12, and therefore between the laminated core and the phase wires in this example, when assembled to the terminal position, resulting in a particularly large tangential force in the circumferential direction U. The slot insulating paper 36 does not pop out. The coil component 10 of the third embodiment is particularly easy to disassemble, does not contain impregnating resin, can be manufactured in a particularly short period of time, has an extremely high degree of slot filling, and enables the phase wires to be positioned in the center of each slot 14.

[0038] Overall, the present invention shows how wedge-shaped slot insulators for the stator windings of an electric machine can be used. [Explanation of symbols]

[0039] 10 Coil parts 12 Holding body 14 slots 16 Hairpin 18 First insulating member 20 channels 22 Collar 24 Contact part 26 First end face 28 Wedge-shaped part 30 Second insulating member 32 Straight line part 34 Wedge part 36 slot insulating paper 38 slot insulating wedge 40 Guide bevel A axis direction U circumferential direction R Radial direction

Claims

1. A coil component (10) for an automotive electric machine, comprising: - a retaining body (12) having a plurality of axially extending slots (14) spaced apart in the circumferential direction (U) of the retaining body (12); - a plurality of hairpin bodies (16) at least partially disposed within said slots (14); - at least one insulating member arranged in one of said slots (14), The insulating member electrically insulates the hairpin body (16) placed in the slot (14) from the slot wall portion of the holder (12) that defines the slot (14), and the insulating members (18, 30, 36) are supported against the slot wall portion of the holder (12) via wedge-shaped portions (28), so that a force acting in the axial direction (A) on the wedge-shaped portions (28) is converted into a force acting in the circumferential direction (U), and this force presses the insulating members (18, 30, 36) against the hairpin body (16) in the circumferential direction (U).

2. The coil component (10) according to claim 1, The coil component is characterized in that the insulating member (18, 30) has the wedge-shaped portion (28) so that two side surfaces of the insulating member (18, 30) intersect at an acute angle.

3. The coil component (10) according to claim 1 or 2, The coil component is characterized in that the insulating members (18, 30) have a U-shaped cross section.

4. The coil component (10) according to claim 2 or 3, A coil component characterized in that a plurality of insulating members (18, 30) are arranged one above the other in the axial direction (A) and are partially inserted in a nested manner within a single slot (14), so that the respective insulating members (18, 30) abut against each other at their respective wedge-shaped portions (28).

5. The coil component (10) according to claim 4, which relies on claim 3, Two insulating members (18) are provided in the slot (14), The legs of the U-shaped cross sections of the insulating members (18) are oriented to face each other, so that the insulating members (18) together surround a channel (20) extending in the axial direction (A), through which the hairpin body (16) extends.

6. In the coil component (10) according to claim 2 or any of claims 3 to 5 which cite claim 2, The insulating member (30) has at least one straight portion (32) having a constant wall thickness extending in the axial direction (A), and at least one wedge-shaped portion (28) adjacent to the straight portion (32) in the axial direction (A).

7. The coil component (10) according to any one of claims 1 to 6, The insulating member (18) has an abutment portion (24) that can abut against one end surface (26) of the holding body (12) and defines the axial end position of the insulating member (18).

8. The coil component (10) according to claim 1, The coil component is characterized in that the insulating member (36) is pressed against the hairpin body (16) by a slot insulating wedge (38) separate from the insulating member and having the wedge-shaped portion (28).

9. A method for manufacturing a coil component (10) for an automotive electric machine, comprising the steps of: The coil component includes a holder (12), and the holder includes a plurality of slots (14) that are arranged at intervals in a circumferential direction (U) of the holder (12) and extend in an axial direction (A); a plurality of hairpin bodies (16) and at least one insulating member (18, 30, 36) are at least partially disposed within said slot (14), said at least one insulating member (18, 30, 36) electrically insulating said hairpin bodies (16) from a slot wall of said retainer (12) defining said slot (14); At least one of the insulating elements (18, 30, 36) is supported against the slot wall of the holding body (12) via a wedge-shaped portion (28), so that the force acting on the wedge-shaped portion (28) in the axial direction (A) is converted into a force acting in the circumferential direction (U), which presses the insulating element (18, 30, 36) against the hairpin body (18) in the circumferential direction (U). method.

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