Coil Groove Closure Element for Higher-Voltage Insulation Reliability
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Solution Overview
Problem
Existing coil components in electric machines face issues with insulation failure due to undesired creep effects and material abrasion, particularly at higher voltages, leading to malfunctions.
Innovation Solution
A coil component design featuring a closure element received in the carrier in a form-fitting manner, with insulation layers projecting beyond winding sections to create a large creepage distance and prevent material abrasion, using a groove closure wedge that is decoupled from the carrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation layers are placed between winding sections and carrier in known designs, then insulation is provided, but current creepage distances are too short for higher voltages and material abrasion occurs during assembly and operation
Solution Approach 1:
The patent introduces a closure element as an intermediary component between the insulation layer and the carrier. This closure element is received in the carrier in a form-fitting manner and is spaced apart from the carrier by the insulation layer's extension portions, creating a physical mediator that increases creepage distance and prevents direct contact that would cause abrasion
Solution Approach 2:
The patent extends the insulation layer radially beyond the winding sections to create extension portions that project towards the radial opening. This dimensional extension in the radial direction creates additional creepage path length and spatial separation, effectively increasing the insulation distance without adding axial height
2Ease of manufacture
If closure element is received directly in carrier, then assembly is simple, but material abrasion occurs during assembly and operation
Solution Approach 1:
The insulation layer with its extension portions acts as a mediator between the closure element and the carrier. The closure element is received in the carrier in a form-fitting manner through the extension portions, which prevents direct metal-to-metal contact during assembly while maintaining simple assembly procedures
Solution Approach 2:
The insulation layer is pre-installed in the carrier grooves before the closure element is assembled. This beforehand cushioning protects the closure element and carrier from direct contact and potential abrasion during the assembly process, while still allowing form-fitting reception
3Reliability
If insulation layer is placed between winding sections and carrier, then insulation is provided, but insulation is subject to material abrasion during assembly and operation
Solution Approach 1:
The closure element serves as a protective intermediary that is received in the carrier in a form-fitting manner through the insulation layer's extension portions. This arrangement protects the insulation layer from direct contact with the carrier during operation, preventing material abrasion while maintaining the insulating effect
Solution Approach 2:
The insulation layer with extension portions is installed beforehand to create a protective barrier. The closure element is then assembled through this pre-positioned insulation layer, which cushions and protects the insulation material from abrasion during both assembly and subsequent operation
Data Source
AI summary
A coil component for an electric machine, having a carrier and a coil winding accommodated in the carrier at least in sections. The carrier has a ring region with multiple grooves distributed in a circumferential direction, and multiple winding sections of the coil winding are received in each groove. An insulation layer is arranged between the carrier and the winding sections in at least one groove and projects with two extension portions over the winding sections towards a radial opening of the at least one groove. A closure element is received in the carrier in the groove with the insulation layer towards the radial opening, and both extension portions are arranged such that the closure element is spaced apart from the carrier by the extension portions. An electric machine is provided with the coil component.