WO2017194444A1 - Method for fixing a coil winding - Google Patents

Method for fixing a coil winding Download PDF

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Publication number
WO2017194444A1
WO2017194444A1 PCT/EP2017/060876 EP2017060876W WO2017194444A1 WO 2017194444 A1 WO2017194444 A1 WO 2017194444A1 EP 2017060876 W EP2017060876 W EP 2017060876W WO 2017194444 A1 WO2017194444 A1 WO 2017194444A1
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WO
WIPO (PCT)
Prior art keywords
polymer material
coil
coil wire
fixing
bobbin
Prior art date
Application number
PCT/EP2017/060876
Other languages
German (de)
French (fr)
Inventor
Thomas Schaefer
Original Assignee
Hilti Aktiengesellschaft
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hilti Aktiengesellschaft filed Critical Hilti Aktiengesellschaft
Publication of WO2017194444A1 publication Critical patent/WO2017194444A1/en

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/12—Insulating of windings
    • H01F41/127—Encapsulating or impregnating
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/2876—Cooling
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/30—Fastening or clamping coils, windings, or parts thereof together; Fastening or mounting coils or windings on core, casing, or other support
    • H01F27/306—Fastening or mounting coils or windings on core, casing or other support
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • H01F27/327—Encapsulating or impregnating
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H01F41/064—Winding non-flat conductive wires, e.g. rods, cables or cords
    • H01F41/066—Winding non-flat conductive wires, e.g. rods, cables or cords with insulation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/12—Insulating of windings
    • H01F41/122—Insulating between turns or between winding layers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/32—Insulating of coils, windings, or parts thereof
    • H01F27/324—Insulation between coil and core, between different winding sections, around the coil; Other insulation structures
    • H01F27/325—Coil bobbins

Definitions

  • the present invention relates to methods of fixing an electrically conductive coil wire to a coil carrier.
  • Electromagnetic machines or components such as electric motors, electromagnets, relays, transformers, measuring coils, loudspeakers or the like, have coils, i. wound wire, to generate or detect magnetic fields.
  • the coils or the wire of the coil is for this purpose acted upon by an electric current.
  • thermally conductive substances are sometimes applied or introduced in upstream and / or downstream working steps and in the winding process.
  • heat is dissipated only superficially, as described, for example, in German patent application DE 102010064072 A1, or very costly heat-conducting materials introduced, for example, by application in the winding process, casting, dipping, trickling, pressing or the like. It is therefore an object of the present invention to solve the problems described above and in particular to provide a method for producing an improved coil. This object is achieved according to the invention by the subject matter of independent claim 1. Further embodiments of the inventive subject matter can be found in the dependent subclaims.
  • a method for fixing an electrically conductive coil wire on a bobbin is to provide, with which eliminates the above problems, a coil wire mounted as effectively as possible on a bobbin and the largest possible heat dissipation can be achieved from a coil out.
  • a method for fixing an electrically conductive coil wire on a coil carrier is provided for this purpose.
  • the method comprises the method steps
  • Coils produced in this way improve the thermal conductivity (> 0.3 Wm / K) and facilitate the fixation of the coil wire on the coil carrier.
  • the heat loss of the coil winding can be increasingly dissipated to the outer surface of the coil, whereby a longer life with a higher resistance to temperature, vibration and erosion can be achieved.
  • coils of more compact dimensions i. possible with a higher power density.
  • the cost can be achieved by choosing a cheaper coil wire quality.
  • the simplified dosage of the fixing or thermally conductive material, the cost can be further reduced.
  • the curing of the polymer material takes place by polymerization, polyaddition or polycondensation.
  • the curing can also be referred to as solidification.
  • the polymer material is both a thermoset material and a thermoplastic material or elastomer material.
  • a particularly good thermal conductivity can be achieved.
  • the thermoset material a Thermal conductivity of greater than 0.3 Wm / K (> 0.3 Wm / K) has. It has been shown that a particularly good heat removal from the coil can be achieved by using a thermosetting material having a thermal conductivity of greater than 0.3 Wm / K (> 0.3 Wm / K).
  • thermoplastic e.g., applying a hot melt adhesive
  • elastomer e.g., applying a silicone
  • the polymer material may also be an adhesive.
  • the winding wires can be fixed in a particularly fast and efficient manner.
  • the polymer material may also be a thermoplastic or an elastomer.
  • the thermoplastic may be a hot-melt adhesive.
  • the elastomer may be silicone.
  • Fig. 1a is a schematic front view of a bobbin with a coil wire during the winding process
  • Figure 1 b is a schematic side view of the bobbin with the coil wire during the winding process.
  • FIG. 2a shows a first detail view of a portion of the bobbin with the coil wire
  • 2b shows a second detail view of a portion of the bobbin with the coil wire.
  • FIG. 1 and 2 show a schematic representation of a bobbin 1 with a coil wire 2 during the winding process.
  • the bobbin 1 essentially comprises a carrier element 3 and a first limiting element 4 and a second limiting element 5.
  • the carrier element 3 has a substantially cylindrical shape.
  • the coil wire 2 consists of at least one metal.
  • the coil wire 2 has a circular diameter cross-section. However, it is also possible that the average cross section of the coil wire 2 has any other possible shape.
  • the first limiting element 4 is configured substantially as a first circular disk 4a
  • the second limiting element 5 is designed essentially as a second circular disk 4b.
  • the second disc 4b has a slightly larger diameter than the first disc 4a.
  • the first disc 4a has a through hole 6, through which the coil wire 2 can be guided.
  • the bobbin 1 or the coil wound from the coil wire 2 can also have any other possible design.
  • a most uniform layer of thermally conductive and curable polymer material 7 is applied to the cylindrical surface 8 of the carrier element 3.
  • the polymer material 7 has the function of an adhesive.
  • the coil wire 2 is wound onto the carrier element 3 of the coil carrier 1 to form a coil or coil winding.
  • the coil wire 2 completely immersed in the still soft polymer material 7, so that the coil wire 2 is completely covered by the polymer material 7.
  • the free end of the coil wire 9 is guided through the through hole 6 in the first disk 4a (see Fig. 1 b).
  • the amount or the height H of the polymer material 7 on the bobbin 1 is chosen so that the wound to the coil coil wire 2 is still covered exactly by the polymer material 7.
  • polymer material 7 may serve to provide additional components, such as e.g. e.g. Cooling elements, bearing shells, components for fixing the coil or bobbin 1 or the like to connect to the bobbin 1.
  • additional components are not shown in the figures.
  • first limiting element 4 and / or second limiting element 4 different through-holes, e.g. Channels, be provided. Additional polymer material 7 can flow through these through-holes or channels for attaching further components or components.
  • connection between bobbin 1 and other components and components e.g. Laminated core or its base insulation, can be further improved by a previous filling of existing holes or channels. The improvement relates in particular to mechanical and thermal connection. Neither the different through holes nor the other components or components are shown in the figures.
  • the polymer material 7 can harden or solidify.
  • the curing or solidification can be carried out for example by polymerization, polyaddition or polycondensation.
  • a hardener eg 2-component polymer / adhesive
  • a trigger eg UV, visible light and / or heat radiation , Humidity, etc.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Insulating Of Coils (AREA)

Abstract

The invention relates to a method for fixing an electrically conductive coil wire on a coil carrier. The method comprises the method steps: applying a thermally conductive and curable polymer material to at least a partial region of the coil carrier; attaching the electrically conductive coil wire to the coil carrier such that the coil wire is covered at least in part by the polymer material; and curing the polymer material for fixing the coil wire by means of cohesion and/or adhesion of the polymer material.

Description

„Verfahren zum Fixieren einer Spulenwicklung" "Method for Fixing a Coil Winding"
Die vorliegende Erfindung bezieht sich auf Verfahren zum Fixieren eines elektrisch leitfähigen Spulendrahts auf einem Spulenträger. The present invention relates to methods of fixing an electrically conductive coil wire to a coil carrier.
Elektromagnetische Maschinen oder Komponenten, wie beispielsweise Elektromotoren, Elektromagnete, Relais, Transformatoren (Trafos), Messspulen, Lautsprecher oder dergleichen, verfügen über Spulen, d.h. gewickelter Draht, zu erzeugen oder detektieren von Magnetfeldern. Die Spulen bzw. der Draht der Spule wird hierzu mit einem elektrischem Strom beaufschlagt. Electromagnetic machines or components, such as electric motors, electromagnets, relays, transformers, measuring coils, loudspeakers or the like, have coils, i. wound wire, to generate or detect magnetic fields. The coils or the wire of the coil is for this purpose acted upon by an electric current.
Strombeaufschlagte Spulen haben energetische Verluste, die zu einer unerwünschten Erwärmung der Spulen führen. Current-loaded coils have energy losses, which lead to unwanted heating of the coils.
Diese Wärme kann nur schlecht nach außen, d.h. an die äußere Oberfläche der Spule, abgeleitet werden, da die Drahtwindungen zueinander keinen großflächigen Kontakt haben. Zusätzlich verbleiben mit den bisher vorhandenen Wicklungsverfahren stets zwischen den Drähten nach dem Wickelvorgang unerwünschte Luftspalte. Zur Beseitigung dieser Probleme können bisher nur Wickeldrähte mit hochwertigeren Qualitäten bzw. deutlich besseren Eigenschaften eingesetzt werden. Dies führt jedoch zu erhöhten Erstellungskosten. This heat can only be bad to the outside, i. to the outer surface of the coil, are derived because the wire windings to each other do not have large-area contact. In addition, undesirable air gaps always remain between the wires after the winding process with the previously existing winding method. To eliminate these problems, only winding wires with higher quality or significantly better properties can be used so far. However, this leads to increased creation costs.
Des Weiteren wäre es möglich, dass größere Bauvolumen für die Wicklungen vorgesehen werden. Größere Bauvolumen sind jedoch aus ökonomischen sowie aus ergonomischen Gesichtspunkten zu vermeiden.  Furthermore, it would be possible for larger volumes to be provided for the windings. However, larger volumes are to be avoided for economic as well as ergonomic considerations.
Als bisherige aufwändige und kostenintensive Maßnahmen werden bisweilen in vorgelagerten und/oder nachgelagerten Arbeitsschritten, und im Wickelprozess integrierten Verfahren, wärmeleitende Stoffe aufgetragen bzw. eingebracht. Dabei wird entweder nur oberflächlich Wärme abgeführt, wie beispielsweise in der deutschen Patentanmeldung DE 102010064072 A1 beschrieben, oder sehr aufwändig wärmeleitende Materialien eingebracht z.B. durch Auftragen im Wickelprozess, Vergießen, Tauchen, Träufeln, Pressen oder dergleichen. Aufgabe der vorliegenden Erfindung ist es daher, die vorstehend beschriebenen Probleme zu lösen sowie insbesondere eine Verfahren zum Erzeugen einer verbesserten Spule bereitzustellen. Diese Aufgabe wird erfindungsgemäss durch den Gegenstand des unabhängigen Anspruchs 1 gelöst. Weitere Ausführungsformen des erfindungsgemässen Gegenstands finden sich in den abhängigen Unteransprüchen. As elaborate and cost-intensive measures hitherto, thermally conductive substances are sometimes applied or introduced in upstream and / or downstream working steps and in the winding process. In this case, heat is dissipated only superficially, as described, for example, in German patent application DE 102010064072 A1, or very costly heat-conducting materials introduced, for example, by application in the winding process, casting, dipping, trickling, pressing or the like. It is therefore an object of the present invention to solve the problems described above and in particular to provide a method for producing an improved coil. This object is achieved according to the invention by the subject matter of independent claim 1. Further embodiments of the inventive subject matter can be found in the dependent subclaims.
Hierzu wird ein Verfahren zum Fixieren eines elektrisch leitfähigen Spulendrahts auf einem Spulenträger zur Verfügung zu stellen, mit dem die vorstehend genannten Probleme beseitigt, ein Spulendraht möglichst effektiv auf einem Spulenträger befestigt und eine möglichst große Wärmeabfuhr aus einer Spule heraus erreicht werden kann.  For this purpose, a method for fixing an electrically conductive coil wire on a bobbin is to provide, with which eliminates the above problems, a coil wire mounted as effectively as possible on a bobbin and the largest possible heat dissipation can be achieved from a coil out.
Ein Verfahren zum Fixieren eines elektrisch leitfähigen Spulendrahts auf einem Spulenträger wird hierzu bereitgestellt.  A method for fixing an electrically conductive coil wire on a coil carrier is provided for this purpose.
Erfindungsgemäss enthält das Verfahren die Verfahrensschritten, According to the invention, the method comprises the method steps
- Auftragen eines wärmeleitfähigen und aushärtbaren Polymerwerkstoff auf wenigstens einen Teilbereich des Spulenträgers;  - Applying a thermally conductive and curable polymer material on at least a portion of the bobbin;
- Anbringen des elektrisch leitfähigen Spulendrahts auf den Spulenträger, sodass der Spulendraht wenigstens teilweise von dem Polymerwerkstoff bedeckt ist; und  - Attaching the electrically conductive coil wire to the bobbin, so that the coil wire is at least partially covered by the polymer material; and
- Aushärten des Polymerwerkstoffs zum Fixieren des Spulendrahts mittels der Kohäsion und/oder Adhäsion des Polymerwerkstoffs. - Curing of the polymer material for fixing the coil wire by means of the cohesion and / or adhesion of the polymer material.
Derart hergestellte Spulen verbessern die Wärmeleitfähigkeit (>0,3Wm/K) und erleichtern die Fixierung des Spulendrahts auf dem Spulenträger. Die Verlustwärme der Spulenwicklung kann verstärkt an die äußere Oberfläche der Spule abführen werden, wodurch eine höhere Lebensdauer mit einer höheren Resistenz gegen Temperatur, Vibration und Erosion erreicht werden kann. Mit dem erfindungsgemäßen Verfahren sind Spulen mit kompakteren Abmessungen, d.h. mit einer höheren Leistungsdichte möglich. Gleichzeitig können die Kosten durch die Auswahl einer günstigeren Spulendrahtqualität erzielt werden. Durch die vereinfachte Dosierung des fixierenden bzw. wärmeleitenden Materials können die Kosten noch weiter gesenkt werden.  Coils produced in this way improve the thermal conductivity (> 0.3 Wm / K) and facilitate the fixation of the coil wire on the coil carrier. The heat loss of the coil winding can be increasingly dissipated to the outer surface of the coil, whereby a longer life with a higher resistance to temperature, vibration and erosion can be achieved. With the method according to the invention, coils of more compact dimensions, i. possible with a higher power density. At the same time, the cost can be achieved by choosing a cheaper coil wire quality. The simplified dosage of the fixing or thermally conductive material, the cost can be further reduced.
Entsprechend einer weiteren vorteilhaften Ausführungsform kann es möglich sein, dass das Aushärten des Polymerwerkstoffs durch Polymerisation, Polyaddition oder Polykondensation erfolgt. Das Aushärten kann auch als Verfestigen bezeichnet werden. According to a further advantageous embodiment, it may be possible that the curing of the polymer material takes place by polymerization, polyaddition or polycondensation. The curing can also be referred to as solidification.
Gemäß einer vorteilhaften Ausführungsform der vorliegenden Erfindung kann vorgesehen sein, dass der Polymerwerkstoff sowohl ein Duroplaste- Werkstoff als auch ein Thermoplaste- Werkstoff oder Elastomer-Werkstoff ist. Hierdurch kann eine besonders gute Wärmeleitfähigkeit erreicht werden. Es kann dabei vorteilhaft sein, dass der Duroplastewerkstoff eine Wärmeleitfähigkeit von größer als 0,3 Wm/K (> 0,3 Wm/K) aufweist. Es hat sich gezeigt, dass durch die Verwendung eines Duroplastewerkstoffs mit einer Wärmeleitfähigkeit von größer als 0,3 Wm/K (> 0,3 Wm/K) eine besonders gute Wärmeabfuhr aus der Spule erreicht werden kann. According to an advantageous embodiment of the present invention can be provided that the polymer material is both a thermoset material and a thermoplastic material or elastomer material. As a result, a particularly good thermal conductivity can be achieved. It may be advantageous that the thermoset material a Thermal conductivity of greater than 0.3 Wm / K (> 0.3 Wm / K) has. It has been shown that a particularly good heat removal from the coil can be achieved by using a thermosetting material having a thermal conductivity of greater than 0.3 Wm / K (> 0.3 Wm / K).
Könnte doch auch ein Thermoplast (z.B. auftragen eines Heissklebstoffes) oder Elastomer (z.B. auftragen eines Silikon) sein, je nach Anforderung (z.B. wenn nur die Spule fixiert/gedämpft werden soll). It could also be a thermoplastic (e.g., applying a hot melt adhesive) or elastomer (e.g., applying a silicone) as needed (e.g., when only the coil is to be fixed / dampened).
Des Weiteren kann es sich bei dem Polymerwerkstoff auch um einen Klebstoff handeln. Hierdurch können auf besonders schnelle und effiziente Art und Weise die Wickeldrähte fixiert werden. Gemäß einer weiteren Ausführungsform kann der Polymerwerkstoff auch ein Thermoplast oder ein Elastomer sein. Bei dem Thermoplast kann es sich um einen Heissklebstoff handeln. Bei dem Elastomer kann es sich um Silikon handeln. Furthermore, the polymer material may also be an adhesive. As a result, the winding wires can be fixed in a particularly fast and efficient manner. According to a further embodiment, the polymer material may also be a thermoplastic or an elastomer. The thermoplastic may be a hot-melt adhesive. The elastomer may be silicone.
Weitere Vorteile ergeben sich aus der folgenden Figurenbeschreibung. In den Figuren sind verschiedene Ausführungsbeispiele der vorliegenden Erfindung dargestellt. Die Figuren, die Beschreibung und die Ansprüche enthalten zahlreiche Merkmale in Kombination. Der Fachmann wird die Merkmale zweckmässigerweise auch einzeln betrachten und zu sinnvollen weiteren Kombinationen zusammenfassen. Further advantages will become apparent from the following description of the figures. In the figures, various embodiments of the present invention are shown. The figures, the description and the claims contain numerous features in combination. The skilled person will conveniently consider the features individually and summarize meaningful further combinations.
Es zeigen:  Show it:
Fig. 1a eine schematische Vorderansicht auf einen Spulenträger mit einem Spulendraht während des Wickelverfahrens;  Fig. 1a is a schematic front view of a bobbin with a coil wire during the winding process;
Fig. 1 b eine schematische Seitenansicht auf den Spulenträger mit dem Spulendraht während des Wickelverfahrens;  Figure 1 b is a schematic side view of the bobbin with the coil wire during the winding process.
Fig. 2a eine erste Detailansicht auf einen Teilbereich des Spulenträgers mit dem Spulendraht; und  2a shows a first detail view of a portion of the bobbin with the coil wire; and
Fig. 2b eine zweite Detailansicht auf einen Teilbereich des Spulenträgers mit dem Spulendraht. 2b shows a second detail view of a portion of the bobbin with the coil wire.
Ausführungsbeispiel: Embodiment:
Fig. 1 und 2 zeigen eine schematische Darstellung eines Spulenträgers 1 mit einem Spulendraht 2 während des Wickelverfahrens.  1 and 2 show a schematic representation of a bobbin 1 with a coil wire 2 during the winding process.
Der Spulenträger 1 enthält im Wesentlichen ein Trägerelement 3 sowie ein erstes Begrenzungselement 4 und ein zweites Begrenzungselement 5.  The bobbin 1 essentially comprises a carrier element 3 and a first limiting element 4 and a second limiting element 5.
Das Trägerelement 3 weist im Wesentlichen eine zylindrische Form auf.  The carrier element 3 has a substantially cylindrical shape.
Der Spulendraht 2 besteht wenigstens aus einem Metall. Der Spulendraht 2 weist einen kreisrunden Durchmesserquerschnitt auf. Es ist jedoch auch möglich, dass der Durchschnittsquerschnitt des Spulendrahts 2 jede andere mögliche Form aufweist.  The coil wire 2 consists of at least one metal. The coil wire 2 has a circular diameter cross-section. However, it is also possible that the average cross section of the coil wire 2 has any other possible shape.
Das erste Begrenzungselement 4 im Wesentlichen als eine erste kreisrunde Scheibe 4a ausgestaltet und das zweite Begrenzungselement 5 ist im Wesentlichen als eine zweite kreisrunde Scheibe 4b ausgestaltet. Wie in den Figuren dargestellt, weist die zweite Scheibe 4b einen etwas größeren Durchmesser auf als die erste Scheibe 4a. Wie in den Figuren angedeutet, weist die erste Scheibe 4a eine Durchbohrung 6 auf, durch die der Spulendraht 2 geführt werden kann. The first limiting element 4 is configured substantially as a first circular disk 4a, and the second limiting element 5 is designed essentially as a second circular disk 4b. As shown in the figures, the second disc 4b has a slightly larger diameter than the first disc 4a. As indicated in the figures, the first disc 4a has a through hole 6, through which the coil wire 2 can be guided.
Der Spulenträger 1 bzw. die aus dem Spulendraht 2 fertig gewickelte Spule können jedoch auch jede andere mögliche Bauform haben.  However, the bobbin 1 or the coil wound from the coil wire 2 can also have any other possible design.
Entsprechend dem erfindungsgemäßen Verfahren zum Fixieren eines elektrisch leitfähigen Spulendrahts auf einem Spulenträger 1 wird in einem ersten Verfahrensschritt eine möglichst gleichmäßige Schicht eines wärmeleitfähigen und aushärtbaren Polymerwerkstoffs 7 auf die zylindrische Oberfläche 8 des Trägerelements 3 aufgetragen. Der Polymerwerkstoff 7 weist dabei die Funktion eines Klebestoffs auf.  In accordance with the method according to the invention for fixing an electrically conductive coil wire to a coil carrier 1, in a first method step a most uniform layer of thermally conductive and curable polymer material 7 is applied to the cylindrical surface 8 of the carrier element 3. The polymer material 7 has the function of an adhesive.
Noch bevor dieser wärmeleitfähige und aushärtbare Polymerwerkstoff 7 aushärten bzw. verfestigen kann, wird der Spulendraht 2 zum Bilden einer Spule bzw. Spulenwicklung auf das Trägerelement 3 des Spulenträgers 1 gewickelt.  Even before this thermally conductive and curable polymer material 7 can harden or solidify, the coil wire 2 is wound onto the carrier element 3 of the coil carrier 1 to form a coil or coil winding.
Wie in den Figuren dargestellt, taucht der Spulendraht 2 dabei vollständig in den noch weichen Polymerwerkstoff 7 ein, sodass der Spulendraht 2 komplett von dem Polymerwerkstoff 7 bedeckt ist. Das freie Ende des Spulendrahts 9 wird durch die Durchbohrung 6 in der ersten Scheibe 4a geführt (vgl. Fig. 1 b). Die Menge an bzw. die Höhe H der Polymerwerkstoff 7 auf dem Spulenträger 1 wird dabei so gewählt, dass der zu der Spule gewickelte Spulendraht 2 noch genau von dem Polymerwerkstoff 7 bedeckt ist. Gemäß einem alternativen Ausführungsbeispiel kann es jedoch auch möglich sein, dass deutlich weniger Polymerwerkstoff 7 auf den Spulenträger 1 aufgetragen wurde als zum Bedecken des zur Spule gewickelten Spulendrahts 2 notwendig wäre und einem weiteren Bearbeitungsschritt (z.B. Spritzpressen, Spritzgießen oder dergleichen) zuzuführen. As shown in the figures, the coil wire 2 completely immersed in the still soft polymer material 7, so that the coil wire 2 is completely covered by the polymer material 7. The free end of the coil wire 9 is guided through the through hole 6 in the first disk 4a (see Fig. 1 b). The amount or the height H of the polymer material 7 on the bobbin 1 is chosen so that the wound to the coil coil wire 2 is still covered exactly by the polymer material 7. However, according to an alternative embodiment, it may also be possible that significantly less polymer material 7 was applied to the bobbin 1 than would be necessary to cover the bobbin wound coil wire 2 and a further processing step (eg transfer molding, injection molding or the like) to supply.
Gemäß einem alternativen Ausführungsbeispiel kann es jedoch auch möglich sein, dass deutlich mehr Polymerwerkstoff 7 auf den Spulenträger 1 aufgetragen wurde als zum Bedecken des zur Spule gewickelten Spulendrahts 2 notwendig wäre. Der überschüssige Polymerwerkstoff 7 kann dazu dienen, zusätzliche Komponenten, wie z.B. z.B. Kühlelemente, Lagerschalen, Bauteile zur Befestigung der Spule bzw. Spulenträgers 1 oder dergleichen, mit dem Spulenträger 1 zu verbinden. Die zusätzlichen Komponenten sind in den Figuren nicht dargestellt. However, according to an alternative embodiment, it may also be possible that significantly more polymer material 7 was applied to the bobbin 1 than would be necessary to cover the bobbin wound to the coil 2. The excess polymeric material 7 may serve to provide additional components, such as e.g. e.g. Cooling elements, bearing shells, components for fixing the coil or bobbin 1 or the like to connect to the bobbin 1. The additional components are not shown in the figures.
Des Weiteren können in dem ersten Begrenzungselement 4 und/oder zweiten Begrenzungselement 4 verschiedene Durchbohrungen, z.B. Kanäle, vorgesehen sein. Zusätzlicher Polymerwerkstoff 7 kann durch diese Durchbohrungen bzw. Kanäle fliessen zur Anbringung weiterer Bauteile oder Komponenten. Zusätzlich kann die Verbindung zwischen Spulenträger 1 und weiteren Komponenten und Bauteile, z.B. Blechpaket oder deren Basisisolation, durch ein vorangegangenes Auffüllen von vorhandenen Durchbohrungen oder Kanälen weiter verbessert werden. Die Verbesserung betrifft insbesondere mechanische und thermische Anbindung. Weder die verschiedenen Durchbohrungen noch die weiteren Bauteile oder Komponenten sind in den Figuren dargestellt.  Furthermore, in the first limiting element 4 and / or second limiting element 4, different through-holes, e.g. Channels, be provided. Additional polymer material 7 can flow through these through-holes or channels for attaching further components or components. In addition, the connection between bobbin 1 and other components and components, e.g. Laminated core or its base insulation, can be further improved by a previous filling of existing holes or channels. The improvement relates in particular to mechanical and thermal connection. Neither the different through holes nor the other components or components are shown in the figures.
Vor, während oder nachdem der Spulendraht 2 und/oder weitere Komponenten bzw. Bauteile mit dem Spulenträger 1 verbunden sind, kann der Polymerwerkstoff 7 aushärten bzw. verfestigen. Das Aushärten bzw. Verfestigen kann beispielsweise durch Polymerisation, Polyaddition oder Polykondensation erfolgen.  Before, during or after the coil wire 2 and / or further components or components are connected to the coil carrier 1, the polymer material 7 can harden or solidify. The curing or solidification can be carried out for example by polymerization, polyaddition or polycondensation.
Des Weiteren kann der Härteprozess durch Zugabe eines Härters (z.B. 2-Komponenten Polymer/Klebstoff) vor, während oder nach dem Auftragen als auch vor, während oder nach dem Auftragen durch Einsatz eines Auslösers (z.B. UV-, sichtbare Licht- und/oder Wärmestrahlung, Feuchtigkeit usw.) gestartet werden. Furthermore, the hardening process by adding a hardener (eg 2-component polymer / adhesive) before, during or after application as well as before, during or after application by using a trigger (eg UV, visible light and / or heat radiation , Humidity, etc.) are started.
Es ist auch möglich, den Polymerwerkstoff 7 in einem vorhergehenden Arbeitsschritt zu fixieren, um ihn im Anschluss an diesen Arbeitsschritt auszuhärten zu lassen (z.B. bei Dual härtenden Polymerwerkstoffen/Klebstoffe). Hierdurch wird eine dauerhafte, fixierende sowie schützende Verbindung hergestellt.  It is also possible to fix the polymer material 7 in a previous working step in order to allow it to be cured after this work step (for example in the case of dual-curing polymer materials / adhesives). As a result, a permanent, fixing and protective connection is made.

Claims

Ansprüche  claims
Verfahren zum Fixieren eines elektrisch leitfähigen Spulendrahts 2 auf einem Spulenträger (1 ), Method for fixing an electrically conductive coil wire 2 on a coil carrier (1),
gekennzeichnet durch die Verfahrensschritten, characterized by the method steps,
- Auftragen eines wärmeleitfähigen und aushärtbaren Polymerwerkstoff (7) auf wenigstens einen Teilbereich des Spulenträgers (1 );  - Applying a thermally conductive and curable polymer material (7) on at least a portion of the bobbin (1);
- Anbringen des elektrisch leitfähigen Spulendrahts (2) auf den Spulenträger (1 ), sodass der Spulendraht (2) wenigstens teilweise von dem Polymerwerkstoff (7) bedeckt ist; und  - Attaching the electrically conductive coil wire (2) on the bobbin (1), so that the coil wire (2) is at least partially covered by the polymer material (7); and
- Aushärten des Polymerwerkstoffs (7) zum Fixieren des Spulendrahts (2) mittels der Kohäsion und/oder Adhäsion des Polymerwerkstoffs (7).  - Curing of the polymer material (7) for fixing the coil wire (2) by means of the cohesion and / or adhesion of the polymer material (7).
Verfahren nach Anspruch 1 , Method according to claim 1,
dadurch gekennzeichnet, dass das Aushärten des Polymerwerkstoffs (7) durch Polymerisation, Polyaddition oder Polykondensation erfolgen. characterized in that the curing of the polymer material (7) by polymerization, polyaddition or polycondensation take place.
Verfahren nach Anspruch 1 oder 2, Method according to claim 1 or 2,
dadurch gekennzeichnet, dass der Polymerwerkstoff (7) sowohl ein Duroplaste- Werkstoff als auch ein Thermoplaste- Werkstoff oder Elastomer-Werkstoff ist. characterized in that the polymer material (7) is both a thermoset material and a thermoplastic material or elastomer material.
PCT/EP2017/060876 2016-05-13 2017-05-08 Method for fixing a coil winding WO2017194444A1 (en)

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EP4047789A1 (en) * 2021-02-18 2022-08-24 Hilti Aktiengesellschaft Thermally enhanced electric motor
EP4401288A1 (en) 2023-01-16 2024-07-17 Hilti Aktiengesellschaft Electric motor, stator for an electric motor, rotor for an electric motor and production method

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EP4047797A1 (en) * 2021-02-18 2022-08-24 Hilti Aktiengesellschaft Improvement of the thermal bonding of electrically conducting coils

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JPS6177315A (en) * 1984-09-25 1986-04-19 Matsushita Electric Works Ltd Manufacture of multi-layer coil
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Publication number Priority date Publication date Assignee Title
EP4047789A1 (en) * 2021-02-18 2022-08-24 Hilti Aktiengesellschaft Thermally enhanced electric motor
EP4401288A1 (en) 2023-01-16 2024-07-17 Hilti Aktiengesellschaft Electric motor, stator for an electric motor, rotor for an electric motor and production method

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