Electric machine with a flat wire winding

Abstract

An electric machine which is suitable for a motor vehicle comprises a rotor and a stator (20). The stator has at least one conductor element (1) which is made of flat wire and can be supplied with current for the main magnetic field. Said conductor element (1) is arranged around at least one magnetic pole, such as a stator tooth of the electric machine. The flat wire has the effect that the or each conductor element (1) has a first side surface (2) which is larger than the second side surfaces. The first side surfaces (2) of one or all of the winding portions (3-6, 14) of the conductor element (1) are perpendicular to a magnetic pole axis, i.e. the longitudinal axis in the case of an axial flux machine or in the radial direction in the case of a radial flux machine. The conductor element is preferably cut or punched out of a strip material, i.e. a thin sheet metal strip, made of aluminum or copper and folded about folding axes (7-9).

Description

[0001] ELECTRIC MACHINE WITH A FLAT WIRE WINDING

[0002] The invention relates to an electric machine, in particular for a motor vehicle, comprising a stator and a rotor rotatable relative to the stator and at least one, in particular foil-like, conductor element which can be energized to generate a magnetic field, wherein the conductor element is arranged at least sectionally around at least one location of a magnetic pole, in particular a stator tooth, of the electric machine.

[0003] Electrical machines of the type mentioned above are, for example, for powering motor vehicles, generally known from the prior art. Particularly in the automotive sector, it is known to optimize the installation space and weight of electrical drive systems, i.e., electrical machines designed to provide torque for propelling the vehicle. In particular, the power density and weight of such electrical machines can be improved by suitable conductor geometries or by special embodiments of the electrical machine. For example, it is known to use a profiled wire as a conductor element instead of a conventional round wire, thereby improving the electrical fill factor. Specifically, it is known that rectangular conductors, for example in the form of foils, can be used as conductor elements in the electrical machine.Such conductor elements are characterized in particular by the fact that they have first side surfaces that are significantly larger than second side surfaces.

[0004] In particular, it is also known that when windings with a high cross-sectional area to surface area ratio are formed at high switching frequencies, negative electromagnetic effects, such as skin effects or proximity effects, can occur, which can negatively affect the performance of the electrical machine.

[0005] The invention is based on the objective of providing an improved electric machine, in particular for a motor vehicle.

[0006] The problem is solved by an electric machine with the features of claim 1. Advantageous embodiments are the subject of the dependent claims.

[0007] As described, the invention relates to an electric machine, specifically for a motor vehicle. The electric machine has a stator and a rotor rotatable relative to the stator. Furthermore, the electric machine has at least one conductor element, in particular a foil-like element, which can be energized to generate a magnetic field. In other words, a defined electric current can be passed through the at least one conductor element to generate a magnetic field in the electric machine. The conductor element is arranged at least partially around at least one location of a magnetic pole of the electric machine.The location of a magnetic pole can also be designed as a "stator tooth", for example when the magnetic pole is formed in a stator of an electric machine, in which the laminated core, from the magnetic return, guides the magnetic field to the intended location of the magnetic pole by means of a projection made of soft magnetic material.

[0008] The present invention also functions without the presence of a soft magnetic "tooth". The described arrangement of the conductor elements or the foil conductors leads to the formation of magnetic poles when a suitable current is applied. Therefore, the electric machine can fundamentally be a radial flux machine or an axial flux machine, whereby the locations of the magnetic poles of the electric machine are arranged differently, or their magnetic pole axes are oriented differently.

[0009] The invention is based on the finding that the at least one conductor element has first side surfaces and second side surfaces, wherein the first side surfaces are larger than the second side surfaces, wherein the first side surfaces of at least one winding section, in particular all winding sections, of the conductor element are arranged perpendicular to a magnetic pole axis, in particular a longitudinal axis, of the location of a magnetic pole of the electrical machine wound by the at least one winding section.

[0010] In other words, the conductor elements, or the winding sections of the at least one conductor element, are arranged in the electrical machine such that their larger first faces are oriented "upright" with respect to the locations of the stator poles. This means that the magnetic pole axis of a location of a magnetic pole surrounded by the winding section of the conductor element is perpendicular to the first faces, which, as described, are larger than the second faces. For example, at a location of a magnetic pole in an axial-flux machine, the magnetic pole axis, for example its longitudinal axis, may run parallel to the axial direction, i.e., parallel to the axis of rotation of the rotor. The first faces of the winding section are therefore also arranged perpendicular to the axis of rotation.In one embodiment of the electric machine, a radial flux machine, the first side faces are also arranged perpendicular to the magnetic pole axis, which, however, runs radially and thus perpendicular to the axis of rotation. Therefore, in the radial flux machine, the first side faces are perpendicular to the radial direction, which can also be related to the axis of rotation of the electric machine, namely perpendicular to it. Regardless of the winding type to be implemented by the conductor element, for example, whether a concentrated winding or a wave winding is to be used, the winding sections are not oriented with their larger first side faces towards the location of a magnetic pole, for example, its magnetic pole flanks, but are perpendicular or "upright" to the location of a magnetic pole.This results in a particularly advantageous positioning of the winding sections relative to the poles, for example, to the field-carrying teeth or stator teeth of the electric machine. With regard to electromagnetic effects, especially skin and proximity effects at higher frequencies, the current is not carried via the comparatively thin side surfaces of the foil-like conductor elements, which limit the current flow, but rather by the significantly larger first side surfaces, since these are oriented perpendicular to the field direction, thus improving the conduction of the electric current within the conductor element. The conductor elements can be rectangular in cross-section or any other shape.

[0011] In other words, the current flow in the described conductor element, which provides at least one winding or at least one winding section for a rotating, single- or multi-phase electrical machine, specifically in the stator of an axial flux machine, is improved. In principle, any material suitable for current flow can be used for the conductor element. For example, the conductor element can be made of or comprise copper. Alternatively, it is equally possible for the conductor element to comprise or be made of aluminum.

[0012] As previously described in general terms, the conductor element has at least one winding section. According to one embodiment of the electric machine, the conductor element can have a stack of winding sections aligned parallel to one another. The stack of winding sections, particularly foil-like ones, of the conductor element is also arranged "upright" in the electric machine, meaning that the larger surface areas of the conductor element are perpendicular to the magnetic pole axes. The conductor element can therefore be based on a foil or a very thin sheet. This allows for a particularly high fill factor. By stacking the foil-like winding sections of the conductor element, fewer dead spaces are formed, especially compared to round wire, thus increasing the power density of the electric machine.

[0013] In a further development of the electric machine, the winding sections can form the conductor element continuously, particularly as a single piece. For example, the conductor element can form a continuous, concentrated winding around at least one stator tooth, such as a stator tooth of an electric machine, whether radial or axial flux. It is also possible to implement the conductor element as a continuously wound wave winding. The individual winding sections can be stacked on top of each other in the axial or radial direction, thus surrounding the teeth of the electric machine's stator. An electrical connection can be provided at the beginning and end of the winding section or conductor element.

[0014] For providing a shaft winding for an axial flux machine, a winding pattern can be used in particular that has outer radial sections and inner radial sections, or radial outer sections and radial inner sections, which, for example, fit into the tooth-gap profile of the electrical machine, especially the axial flux machine or the stator teeth. The inner radial sections are connected to circumferentially adjacent outer radial sections by flank sections, and vice versa. The flank sections are essentially oriented in the radial direction or connect the outer sections to the inner sections.

[0015] In other words, the circumferential pattern consists of an outer radial section connected via a flank section to an inner radial section, which in turn is connected via a flank section to a subsequent outer radial section further along the circumference. This pattern is continued arbitrarily between the ends or connection elements of the conductor element or winding section. Furthermore, it can begin and / or end with either an inner or an outer radial section. If a wave winding is provided for a radial flux machine, the individual winding sections surrounding the magnetic poles, for example, the stator teeth, are essentially S-shaped or meandering. The at least one winding section comprises, for example, axial sections running parallel to the axial direction, which are connected to each other via circumferential sections.

[0016] The described electrical machine can be further developed such that the winding sections of the conductor element have primary insulation, in particular an oxide layer applied to the first faces of the conductor element. Instead of a plastic layer typically used for insulation in the prior art, a significantly smaller primary insulation layer can be used. The described primary insulation, for example the oxide layer, protects stacked winding sections of the conductor element from electrical contact, so that they are electrically insulated from each other at their first faces. This ensures that no short circuit occurs between the winding sections.By using the described primary insulation, particularly the oxide layer, the temperature limits of the electric machine can be significantly increased, especially compared to commonly used plastics. For example, the primary insulation can be applied ceramically or anodized. The oxide layer can be a few micrometers thick, for example, 1 to 10 pm, or even 3 pm. Furthermore, compared to commonly used insulating layers, the primary insulation in the form of an oxide layer is cost-effective to produce.

[0017] The individual winding sections, which, for example, form individual windings or partial windings of the conductor element, can be folded together along folding axes to create sections of a conductor element manufactured in one piece, particularly by laser cutting or stamping. The individual winding sections can be manufactured as single pieces, and individual winding sections or groups of winding sections can be interconnected. Likewise, the entire conductor element comprising the individual winding sections can be manufactured as a single piece. The folding axes can be integrated into the pattern as desired, so that, for example, winding sections forming half or quarter windings, or any other partial sections of a winding, can be created from the winding pattern by folding along the folding axes.

[0018] Advantageously, this allows for the creation of a continuous pattern arranged in a linear direction, for example, by punching or cutting. Specifically, the winding pattern can be obtained from a material supplied on a strip. The strip material can be unwound, and the winding pattern cut out of the strip material by punching or cutting, particularly laser cutting. Subsequently, the winding sections can be obtained by defined folding of the winding pattern along the fold axes, thus forming the conductor element.

[0019] Furthermore, the electric machine can be designed with two successive winding sections folded in opposite directions along folding axes that delineate the two winding sections. The previously described stack of winding sections arranged radially or axially, depending on the machine type, can be obtained, in particular, by folding two winding sections—which, for example, belong to two different windings or follow one another or are adjacent in the winding pattern—in opposite directions along folding axes that separate the two windings from each other or divide them into the different windings. In other words, windings that form the individual windings of the conductor element can advantageously be produced from the previously described strip material by successive folding processes from the individual winding sections.The winding sections can always be folded in opposite directions, i.e., in opposite folding directions.

[0020] As previously described, the folding axes can be arranged differently depending on the winding pattern, or the individual folding operations can be carried out along differently oriented folding axes. The folding axes can, for example, be oriented vertically or at a defined angle, such as along a longitudinal axis of the tape material or the winding pattern.

[0021] Specifically, the electrical machine may be designed so that two conductor elements are manufactured from a single blank as adjacent pattern tracks, particularly perpendicularly adjacent with respect to a longitudinal direction of the blank. As described, the at least one conductor element may be manufactured from a strip material, for example by stamping or cutting. Pattern tracks for at least two conductor elements can be arranged or fixed, i.e., positioned, on the same blank in such a way that the at least two conductor elements can be manufactured as adjacent pattern tracks, for example by cutting or stamping them out.

[0022] This allows, in particular, the combination of multiple pattern strips for conductor elements on the same blank, resulting in less overall waste and enabling faster and more efficient production of the individual conductor elements. In other words, one blank is provided from which at least two pattern strips for two different conductor elements are produced. The separation lines for the pattern strips, where the blank is cut to remove or punch out the pattern strips for the conductor elements, can be positioned on the blank in such a way as to minimize waste and dead space.

[0023] As described at the outset, the electric machine can be configured as either an axial flux machine or a radial flux machine. The arrangement and orientation of the winding sections, particularly the orientation of their first faces, may be determined by the machine type. In one embodiment, the electric machine can be configured as an axial flux machine with the conductor element as a concentrated winding or a wave winding, or it can be configured as a radial flux machine with the conductor element as a concentrated winding or a wave winding. In either case, the stator of the electric machine can also be segmented, for example, as a star-yoke segmentation.As already described, the number of conductor elements can also be chosen arbitrarily, for example depending on the number of phases of the electrical machine, which, as described, can be single-phase or multi-phase.

[0024] In the design of concentrated windings, the conductor element or the at least one winding section is wound, with the first side faces arranged vertically, as described. As described, the magnetic pole axis in the axial flux machine runs parallel to the axis of rotation of the electrical machine, whereas in the radial flux machine, the magnetic pole axis runs radially, i.e., towards the axis of rotation. If the at least one winding section or the at least one conductor element is designed as a wave winding, it can be expanded from radially inside to radially outside in the radial flux machine and thus inserted into the spaces between the teeth. In the design as an axial flux machine, the wave winding can be generated and inserted axially between the teeth of the axial flux machine, so that it surrounds the teeth of the electrical machine in a wave-like manner, particularly on three sides.

[0025] In addition to the electric machine, the invention relates to a motor vehicle comprising a previously described electric machine. The invention further relates to a method for manufacturing an electric machine, in particular a previously described electric machine, comprising a stator and a rotor rotatable relative to the stator and at least one, in particular foil-like, conductor element that can be energized to generate a magnetic field, wherein the conductor element is arranged at least sectionally around at least one location of a magnetic pole, in particular a stator tooth, of the electric machine, comprising the steps:

[0026] Cutting the conductor element having several winding sections from a raw material, in particular a foil;

[0027] Folding of the conductor element at at least one folding axis arranged between two winding sections;

[0028] Arranging the folded conductor element in the electrical machine, wherein the first side surfaces of the conductor element, which are larger than the second side surfaces of the conductor element, of at least one winding section, in particular of all winding sections, of the conductor element, are arranged perpendicular to a location of a magnetic pole axis, in particular a longitudinal axis, of the location of a magnetic pole of the electrical machine wound by the at least one winding section.

[0029] All the advantages, details, and features described in relation to the electric machine are fully transferable to the motor vehicle and the method. In particular, the method described herein can be used to manufacture a previously described electric machine, or at least a conductor element for such an electric machine, in all its details.

[0030] The invention is explained below with reference to exemplary embodiments and the figures. The figures are schematic representations and show:

[0031] Fig. 1 shows a schematic representation of a winding pattern of a conductor element according to a first embodiment in a first manufacturing state;

[0032] Fig. 2 shows the winding pattern of Fig. 1 in a second manufacturing state;

[0033] Fig. 3 shows a schematic representation of a winding pattern of a conductor element according to a second embodiment;

[0034] Fig. 4 shows a schematic representation of a winding pattern of a conductor element according to a third embodiment;

[0035] Fig. 5 shows a schematic representation of a winding pattern of a conductor element according to a fourth embodiment;

[0036] Fig. 6 shows a schematic representation of a winding pattern of a conductor element according to a fifth embodiment;

[0037] Fig. 7 shows a schematic representation of a conductor element according to a sixth

[0038] Example implementation;

[0039] Fig. 8 shows a schematic representation of a conductor element according to a seventh

[0040] Example implementation;

[0041] Fig. 9 shows a schematic representation of a section of an electrical machine according to an eighth embodiment;

[0042] Fig. 10 shows a schematic representation of several winding patterns according to a ninth winding.

[0043] Example implementation;

[0044] Fig. 11 shows a schematic representation of a conductor element according to a tenth

[0045] Exemplary embodiment; Fig. 12 shows a schematic representation of a manufacturing process of the conductor element according to Fig. 11 when inserted into a stator of an electric machine;

[0046] Fig. 13 shows a schematic representation of a section of an electrical machine; and

[0047] Fig. 14 shows a schematic representation of a section of an electrical machine according to an eleventh embodiment.

[0048] Fig. 1 shows a schematic representation of a conductor element 1 for an electric machine, which may be specifically intended for use in a motor vehicle, in particular as a traction drive for the motor vehicle. The following description is therefore also applicable to a motor vehicle comprising such an electric machine, with reference to the other figures. The conductor element 1 is designed in a foil-like form, meaning that the first side surfaces 2, shown in plan view in Figs. 1-4, are significantly larger than the second side surfaces, which run perpendicular to the plane of the drawing and constitute the "height" or material thickness of the conductor element 1.

[0049] Figure 1 shows that the conductor element 1 comprises, by way of example, four winding sections 3-6, which, by folding along folding axes 7-9, form, by way of example, two windings 10 (compare Figures 2, 5, 6). The geometry of the winding sections 3-6 and their number can be adapted to the respective electrical machine. For example, at folding axis 7, winding section 4 is folded onto winding section 3, and at folding axis 8, winding section 5 is folded in the opposite direction onto winding section 4. At folding axis 9, winding section 6 is folded onto winding section 5 in the same direction in which winding section 4 was folded onto winding section 3. It is evident that, depending on the number of windings 10 required, the configuration shown in Figure 1 can be adapted to the specific electrical machine.The winding pattern shown in 1 can be continued so that the folded conductor element 1 can be created by folding the winding sections 3-6 accordingly.

[0050] The winding sections 3-6 form a stack 11 of windings 10 in the conductor element 1, as shown, for example, in Fig. 5-8. These windings 10, as well as the winding sections 3-6 that form them, are aligned parallel to each other, i.e., their first side surfaces 2 are aligned parallel to each other. As shown, for example, in Fig. 1-4, the winding sections 3-6, and thus the basic shape of the entire conductor element 1, can be continuously produced from a blank, for example, by cutting, in particular laser cutting, or punching. The blank can, for example, be a strip-shaped raw material, such as a foil or a thin sheet, in particular made of aluminum or copper. The winding sections 3-6 cut or punched from the blank can then be folded along the folding axes 7-9, as described, to produce the conductor element 1 comprising the windings 10.

[0051] Figure 2 shows an intermediate state in which winding section 4 has been folded onto winding section 3 along the folding axis 7. As already described, winding section 5 can then be folded onto winding section 4 along the folding axis 8, and subsequently, again in the opposite direction, winding section 6 can be folded onto winding section 5 along the folding axis 9. The conductor element 1 has connection elements 12 at its ends, which serve for electrical contacting the conductor element 1, in particular for connecting it to a current source or voltage source of the electric machine 1.

[0052] Fig. 3 shows a conductor element 1 or a winding pattern for a conductor element 1 according to a second embodiment. The basic structure of the conductor element 1 in Fig. 3 follows the structure of the conductor element 1 from Figs. 1 and 2. The manufacturing process, in particular by folding the individual winding sections 3-6, is therefore completely transferable. In contrast to the representation in Figs. 1 and 2, the connection elements 12 are oriented radially and thus point towards a center of the conductor element 1.

[0053] Fig. 4 shows another winding pattern that can, for example, be cut or punched out of a blank. In contrast to the embodiments in Figs. 1-3, the folding axes 7-9, 13 are not oriented perpendicular to a longitudinal axis of the conductor element 1 or the winding sections 3-6, but run diagonally to it or at a defined angle, for example 45°.

[0054] In principle, the production of the conductor element 1 from the individual winding sections 3-6, 14 can be applied analogously to the pattern described above. For example, winding section 4 is folded onto winding section 3 along folding axis 7, while winding section 5 is folded onto winding section 4 along folding axis 8 in the opposite direction. Subsequently, winding section 6 is folded onto winding section 5 along folding axis 9 in the opposite direction, and finally, winding section 14 is folded onto winding section 6 along folding axis 13. The folding direction alternates with each folding process. As already described, the number of winding sections 3-6, 14 and folding axes 7-9, 13 can be increased as needed to create the required number of windings 10.

[0055] Fig. 5 shows a schematic intermediate state of the conductor element 1, for example based on the winding pattern according to Fig. 3, in which the individual winding sections 3-6 are partially folded on top of each other. Likewise, Fig. 6 shows a partially folded conductor element 1, for example according to Fig. 4, in which the individual winding sections 3-6, 14 are folded on top of each other.

[0056] Figures 7 and 8 also show, purely schematically, conductor elements 1 that were produced from the winding patterns or the individual winding sections 3-6, for example according to Figures 1, 2, and 3. It is evident that the winding sections 3-6 form windings 10, which lie on top of each other as a stack 11, with the first side surfaces 2 of the winding sections 3-6 being aligned parallel to each other.

[0057] As can be further seen in Figures 1-8, each winding section 3-6, 14 in the described embodiments, particularly with respect to a rotational axis 18 of the electric machine running centrally through the winding sections 3-6, 14 or the conductor element 1, has outer sections 15 and inner sections 16, which can also be referred to as radial outer sections 15 and radial inner sections 16. Each outer section 15 is connected to an inner section 16 via a flank section 17, and each inner section 16 is connected to an outer section 15 via a flank section 17, or a flank section 17 is arranged between an inner section 16 and an outer section 15, and vice versa. The conductor elements 1 shown in Figures 1-8 are particularly intended for installation in an electric machine designed as an axial flux machine.

[0058] This allows the locations of the magnetic poles, for example the stator teeth, of the electric machine to be surrounded by three sections of the conductor element 1, namely by two flank sections 17 and an outer section 15 or an inner section 16. The stack 11 of windings 10 forming the conductor element 1 can thus be inserted axially into the electric machine or its stator, so that the locations of the magnetic poles are surrounded by the winding sections 3-6, 14 on at least three sides.

[0059] Fig. 9 shows a schematic section, in particular a cross-section, of an electric machine 1, which has several conductor elements 1, manufactured, for example, as described above. The electric machine can be designed as a multiphase electric machine, in particular as a three-phase electric machine. The individual stacks 11 of the conductor elements 1 are arranged circumferentially offset from one another in the electric machine 1. Furthermore, the axis of rotation 18 of the electric machine is shown schematically in Fig. 9. The first side surfaces 2 of the conductor elements 1, or of the winding sections 3-6, are perpendicular to the axis of rotation 18. The conductor elements 1 are therefore arranged in the electric machine in a vertical orientation. It follows that the first side surfaces 2 are perpendicular to both the axis of rotation 18 and the axial direction.the axially extending magnetic pole axis of the locations of the magnetic poles of the electric machine.

[0060] Fig. 10 shows another embodiment of manufacturing conductor elements 1 from a blank. In principle, the conductor elements 1 can be shaped as desired, for example, as described with reference to Figs. 1-9. In addition, Fig. 10 shows that several winding patterns for different conductor elements 1 can be arranged on the same blank. This reduces the amount of material wasted in the blank and increases the process speed, since more than one conductor element 1 can be produced from the same blank, for example, by stamping or cutting.

[0061] As described, the conductor elements 1 shown in Figs. 1-10 are intended for use in electrical machines designed as axial flux machines. Figs. 11-13 show an embodiment of a conductor element 1 intended for use in a radial flux machine. As can be seen in Fig. 11, the conductor elements 1 are also formed from a stack 11 of winding sections 3-6 arranged radially. The conductor elements 1 are also designed in a foil-like manner, such that they have first side surfaces 2 that are significantly larger relative to their area than second side surfaces, which are oriented axially. In contrast, the first side surfaces 2 are oriented radially and thus point in the direction of the axis of rotation 18 of the electrical machine.

[0062] In this embodiment as well, the winding sections 3-6 can surround the magnetic pole locations of the electric machine, which are placed in receiving spaces 19 formed by the conductor element 1. In the radial flux machine, the magnetic pole locations of the stator, or the stator teeth, extend with their magnetic pole axis in the radial direction, i.e., in the direction of the axis of rotation 18. Therefore, the first side surfaces 2 of the conductor elements 1 are oriented both perpendicular to the radial direction and perpendicular to the magnetic pole axis extending in the radial direction.

[0063] Figures 12 and 13 show, by way of example, the insertion of a conductor element 1 into a stator 20 of the electric machine. The stack 11, shown in Figure 11, is inserted axially into a stator opening, and the winding sections 3-6 of the conductor element 1 are placed around the locations of the magnetic poles, for example, around the stator teeth 21.

[0064] Instead of the wave winding shown in Figs. 1-13, concentrated windings can also be used in both axial and radial flux machines. Fig. 14 shows an example of a cross-section in the region of a stator tooth 21, for example for an axial flux machine, where the stator tooth 21 is wound by several windings 10. The stator tooth 21 is clearly oriented axially, i.e., in the same direction as the axis of rotation 18. The first side faces 2 of the conductor element 1, which has the windings 10, are perpendicular to the axis of rotation 18 or the magnetic pole axis of the stator tooth 21, which is also oriented axially or parallel to it. It is also possible to create a concentrated winding for a radial flux machine in which only the magnetic pole axis does not run axially, but radially.It is possible to insert a stack 11 of windings 10 of a conductor element 1 around the stator teeth 21 in the same way, wherein the conductor elements 1 are not inserted in the axial direction over the stator tooth 21, but in the radial direction.

[0065] It is also possible to segment the stator 20 of the electric machine accordingly, so that the resulting individual segments together form the stator 20. The stator teeth 21 of the individual segments can be wound separately with conductor elements 1 or winding sections 3-6, 14. The conductor elements 1 or the winding sections 3-6, 14 can then be interconnected or electrically contacted. Each of the conductor elements 1 can have primary insulation, specifically an oxide layer. The primary insulation can be comparatively thin, for example less than 10 pm, applied to or formed on the first side surfaces 2.

[0066] REFERENCE SIGN EN

[0067] Conductor element first side surface -6 Winding section -9 Folding axis 0 Winding 1 Stack 2 Connection element 3 Folding axis 4 Winding section 5 Outer section 6 Inner section 7 Flank section 8 Rotation axis 9 Receiving space 0 Stator 1 Stator tooth

Claims

Godparents' Sayings 1. An electric machine, in particular for a motor vehicle, comprising a stator (20) and a rotor rotatable relative to the stator (20) and at least one, in particular foil-like, conductor element (1, T) which can be energized to generate a magnetic field, wherein the conductor element (1, T) is arranged at least sectionally around at least one location of a magnetic pole, in particular a stator tooth (21), of the electric machine, characterized in that the at least one conductor element (1, T) has first side surfaces (2) and second side surfaces, wherein the first side surfaces (2) are larger than the second side surfaces, wherein the first side surfaces (2) form at least one winding section (3-6, 14), in particular all Winding sections (3-6, 14) of the conductor element (1, T) are arranged perpendicular to a magnetic pole axis, in particular a longitudinal axis, of the location of a magnetic pole of the electrical machine which is wound by at least one winding section (3-6, 14).

2. Electric machine according to claim 1 , characterized in that the conductor element (1 , T) has a stack (11) of winding sections (3-6, 14) aligned parallel to each other.

3. Electrical machine according to claim 1 or 2, characterized in that the winding sections (3-6, 14) form the conductor element (1 , T) continuously, in particular in one piece.

4. Electrical machine according to one of the preceding claims, characterized in that the winding sections (3-6, 14) of the conductor element (1, T) have primary insulation, in particular an oxide layer applied to the first side surfaces (2) of the conductor element (1, T).

5. Electrical machine according to one of the preceding claims, characterized in that the winding sections (3-6, 14) form sections of a conductor element (1, T) folded on top of each other on folding axes (7-9, 13), which is manufactured in one piece, in particular by means of laser cutting or punching.

6. Electric machine according to one of the preceding claims, characterized in that two successive winding sections (3-6, 14) in the winding direction are arranged in opposite directions along two The winding sections (3-6, 14) are folded along the folding axes (7-9, 13) that define the folding axes.

7. Electrical machine according to one of the preceding claims, characterized in that two conductor elements (1, T) are produced as adjacent pattern tracks from a raw part.

8. Electrical machine according to one of the preceding claims, characterized in that the electrical machine is designed as an axial flux machine, wherein the conductor element (1, T) is designed as a concentrated winding or wave winding, or that the electrical machine is designed as a radial flux machine, wherein the conductor element (1, T) is designed as a wave winding.

9. Motor vehicle comprising an electric machine according to any of the preceding claims.

10. Method for manufacturing an electric machine, in particular an electric machine according to one of claims 1 to 8, comprising a stator (20) and a rotor rotatable relative to the stator (20) and at least one, in particular foil-like, conductor element (1, 1') which can be energized to generate a magnetic field, wherein the conductor element (1 , T) is arranged at least sectionally around at least one location of a magnetic pole, in particular a stator tooth, of the electric machine, characterized by the steps: Cutting the conductor element (1 , T) having several winding sections (3-6, 14) from a raw material, in particular a foil; Folding of the conductor element (1, T) on at least one folding axis (7-9, 13) arranged between two winding sections (3-6, 14); Arranging the folded conductor element (1, T) in the electrical machine, wherein the first side surfaces of the conductor element (1, 1'), which are larger than the second side surfaces of the conductor element (1, T) of at least one winding section (3-6, 14), in particular of all winding sections (3-6, 14), of the conductor element (1, T), are arranged perpendicular to the axis of rotation of the electrical machine and perpendicular to a magnetic pole axis, in particular a longitudinal axis, of the location of a magnetic pole of the electrical machine wound by the at least one winding section (3-6, 14).

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