Winding support and stator

Abstract

A winding support (100) that serves to at least partially accommodate a stator coil of a stator, whereby the winding support (100) has a plurality of protrusions (1, 2, 3, 4, 5, 6) that can each be inserted in an insertion direction (E) into a cavity that is formed by two adjacent stator pole teeth of a laminated core of the stator, whereby at least one of the protrusions (1, 3, 5) has a different length in the insertion direction (E) than at least one of the other protrusions (2, 4, 6).

Claims

1. A winding support serves to at least partially accommodate a stator coil of a stator, the winding support comprising: a plurality of protrusions insertable in an insertion direction into a cavity formed by two adjacent stator pole teeth of a laminated core of the stator, at least one of the protrusions having a different length in the insertion direction than at least one of the other protrusions and wherein at least two adjacent protrusions have a same length; wherein at least two other adjacent protrusions each have a different length from the same length.

2. The winding support as recited in claim 1 wherein the at least two other protrusions are each of a further same length.

3. The winding support as recited in claim 1 wherein the at least two adjacent protrusions having the same length include three adjacent protrusions have the same length.

4. The winding support as recited in claim 1 wherein the winding support is made of an electrically insulating plastic and the protrusions are connected to each other in the form of a ring.

5. A stator for an electric motor, the stator comprising: a laminated core with a plurality of stator pole teeth, each pair of adjacent teeth forming a cavity; and a first and second winding supports, each as recited in claim 1, whose protrusions are inserted into the cavities in such a way that a longer protrusion of the first winding support and a shorter protrusion of the second winding support are located in the same cavity.

6. The stator as recited in claim 5 wherein the first and second winding supports are configured to be complementary to each other.

7. The stator as recited in claim 5 wherein the winding supports are rotated by a given angle relative to each other, the given angle being 360 degrees/number of stator pole teeth.

8. The stator as recited in claim 5 wherein each surface oriented normal to the insertion direction situated within a total length of the laminated core intersects at least one of the protrusions.

9. The stator as recited in claim 5 wherein air gaps each equal in size are provided between the protrusions of the first winding support and the corresponding protrusions of the second winding support relative to the insertion direction.

10. The stator as recited in claim 5 wherein the protrusions of the first winding support and the corresponding protrusions of the second winding support overlap, relative to the insertion direction, a thus-defined overlapping area being larger than a thickness of individual laminations of the laminated core.

11. The stator as recited in claim 10 wherein the thus-defined overlapping area is at least 5 times larger than the thickness of the individual laminations of the laminated core.

12. The stator as recited in claim 5 wherein the winding support is made of an electrically insulating plastic and the protrusions are connected to each other in the form of a ring.

13. An electric motor comprising a stator as recited in claim claim 5.

14. A hand-held power tool comprising the electric motor as recited in claim 13.

15. The winding support as recited in claim 3 wherein three other adjacent protrusions each have a different same length than the same length.

16. The winding support as recited in claim 15 wherein the plurality of protrusions number exactly six.

17. A winding support serves to at least partially accommodate a stator coil of a stator, the winding support comprising: a plurality of protrusions insertable in an insertion direction into a cavity formed by two adjacent stator pole teeth of a laminated core of the stator, at least one of the protrusions having a different length in the insertion direction than at least one of the other protrusions and wherein at least two adjacent protrusions have a same length and wherein the at least two adjacent protrusions having the same length include three adjacent protrusions have the same length.

18. The winding support as recited in claim 17 wherein three other adjacent protrusions each have a different same length than the same length.

19. The winding support as recited in claim 18 wherein the plurality of protrusions number exactly six.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Identical and similar components are designated in the figures with the same reference numerals. The following is shown:

(2) FIG. 1 a stator known from the state of the art;

(3) FIG. 2 a second stator known from the state of the art, with stator coils;

(4) FIG. 3 a preferred embodiment of a winding support according to the invention;

(5) FIG. 4A the winding support shown in FIG. 3, with a complementary (second) winding support;

(6) FIG. 4B a partial view of two complementary winding supports;

(7) FIG. 5 a stator with the winding supports shown in FIG. 4A, fitted with stator coils;

(8) and

(9) FIG. 6 a hand-held power tool with a electric motor and a stator; and

(10) FIG. 7 an alternate embodiment of a winding support according to the invention.

DETAILED DESCRIPTION

State of the Art

(11) FIG. 1 shows a stator 500 known from the state of the art. The stator 500 has a laminated core 400 with six stator pole teeth 10, 20, 30, 40, 50, 60, whereby each of two adjacent teeth form a cavity 12, 23, 34, 45, 56, 61.

(12) The stator 500 likewise has a first winding support 100 and a second winding support 100′. The winding supports 100, 100′ have not been inserted into the laminated core 400.

(13) The first winding support 100 has six protrusions 1, 2, 3, 4, 5, 6 that are each to be inserted in an insertion direction E into the appropriate cavity 12, 23, 34, 45, 56, 61 of the laminated core 400 of the stator 500. The second winding support 100 likewise has six protrusions 1′, 2′, 3′, 4′, 5′, 6′ that are each to be inserted in an insertion direction E′ into the appropriate cavity 12, 23, 34, 45, 56, 61 of the laminated core 400 of the stator 500.

(14) The six protrusions 1, 2, 3, 4, 5, 6 of the first winding support 100 and the six protrusions 1′, 2′, 3′, 4′, 5′, 6′ of the second winding support 100′ each have identical lengths, relative to their appertaining insertion direction E, E′.

(15) FIG. 1 shows a structurally minimal solution of the winding supports 100, 100′ in which the protrusions 1, 2, 3, 4, 5, 6; 1′, 2′, 3′, 4′, 5′, 6′ extend into the laminated core 400 only by a relatively short distance, that is to say, essentially in the area of a winding head K, K′ at the beginning and at the end of the laminated core 400.

(16) FIG. 2 shows another stator 500 known from the state of the art. For the sake of clarity, a sectional view was selected in which three (of six) stator coils 310, 320, 330 can be seen. The laminated core 400 is identical to the laminated core 400 shown in FIG. 1.

(17) The winding supports 100, 100′ inserted into the laminated core 400 insulate the laminated core 400 over the entire length of the laminated core GL, whereby each of the winding supports 100, 100′ covers about half the length of the laminated core GL. A gap SP remains in the middle of the laminated core 400 in order to compensate for the length tolerance of the laminated core 400.

(18) In FIG. 2, in the stator 400 according to the state of the art, the continuously circumferential compensation gap SP that remains between the winding supports 100, 100′ forms an undesired rupture point. In other words, there is at least one surface FL0 that is oriented normal to the insertion direction E, E′ and that is situated within the total length GL of the laminated core 400 and that does not intersect any of the protrusions 1, 2, 3, 4, 5, 6; 1′, 2′, 3′, 4′, 5′, 6′.

Embodiments

(19) FIG. 3 shows a preferred embodiment of a winding support 100 according to the invention. The winding support 100 is configured to at least partially accommodate a stator coil 300, 320, 330 (see FIG. 5) of a stator 500.

(20) The winding support 100 has precisely six protrusions 1, 2, 3, 4, 5, 6. The protrusions 1, 2, 3, 4, 5, 6 are each to be inserted in an insertion direction E into a cavity 12, 23, 34, 45, 56, 61 (see FIG. 1) that is formed by two adjacent stator pole teeth 60, 10; 10, 20; 20, 30; 30, 40; 40, 50; 50, 60 of a laminated core 400 of a stator 500 (see FIG. 1).

(21) In the embodiment shown in FIG. 3, precisely three of the protrusions 1, 3, 5 in the insertion direction E have different, namely, greater lengths than the remaining other protrusions 2, 4, 6. Here, two immediately adjacent protrusions 1, 2; 2, 3; 3, 4; 4, 5; 5, 6; 6, 1 each have different lengths. In other words, a short protrusion 2, 4, 6 and a long protrusion 1, 3, 5 are distributed alternately along the circumference U of the winding support 100.

(22) The winding support 100 is made of an electrically insulating plastic and the protrusions 1, 2, 3, 4, 5, 6 are connected to each other in the form of a ring, in the present embodiment, by means of an appertaining connecting ring 110.

(23) FIG. 4A shows the winding support 100 of FIG. 3, with a complementary second winding support 100′ (at the bottom in FIG. 4A).

(24) The first winding support 100 and the second winding support 100′ have an identical configuration as far as the protrusions 1, 2, 3, 4, 5, 6; 1′, 2′, 3′, 4′, 5′, 6′ are concerned. Here, the winding supports 100, 100′ are rotated by a given angle W relative to each other, whereby the angle is 60 degrees, since the winding supports 100, 100′ are configured for a laminated core with precisely six stator pole teeth 10, 20, 30, 40, 50, 60 (see FIG. 1).

(25) The protrusions 1, 2, 3, 4, 5, 6; 1′, 2′, 3′, 4′, 5′, 6′-based on the depiction in FIG. 4A—would be inserted into the cavities in such a way that a longer protrusion 1 of the first winding support 10 and a shorter protrusion 6′ of the second winding support 100′ are located in the same cavity 12.

(26) It should be pointed out that here, the first and second winding supports 100, 100′ have structural differences in the area of the winding heads K, K′ and structural differences on each of their sides of the connecting rings 110, 110′ facing away from the laminated core (not shown here).

(27) Making reference to FIG. 4B, an overlapping of protrusions will be explained below by way of an example. For this purpose, FIG. 4B shows a partial view of two complementary winding supports 100, 100′.

(28) The longer protrusion 1 of the first winding support 100 and the shorter protrusion 6′ of the second winding support 100′ complement each other in terms of their length relative to the total length GL of the laminated core 400, minus an air gap SP1 (LL+KL=GL−SP1) when the winding supports 100, 100′ are inserted all the way into the laminated core 400 (this is shown in FIG. 4B).

(29) By the same token, the shorter protrusion 2 of the first winding support 100 and the longer protrusion V of the second winding support 100′ complement each other in terms of their length relative to the total length GL of the laminated core 400, minus an air gap SP2 (LL+KL=GL−SP2). Relative to the insertion direction E, E′, the air gaps SP1, SP2 have the same length.

(30) By way of example, at a total length GL of the laminated core 400 amounting to 27 mm, the long protrusions 1, 1′ have a length LL of 15 mm while the short protrusions 2, 6′ have a length KL of 11 mm. The air gaps SP1, SP2 are each 1 mm long. The protrusions 1, 2 of the first winding support 100 and the corresponding protrusions 6′, 1′ of the second winding support 100′ overlap, relative to the insertion direction E, E′, in an overlapping area UB, that is thus, for instance, 3 mm wide by way of example. The overlapping area UB is also at least 5 times greater than the thickness of the individual laminations EB of the laminated core 400, which is, for instance, 0.35 mm.

(31) FIG. 5 shows a stator 500 with a laminated core 400 into which the winding supports 100, 100′ of FIG. 4A have been properly inserted. For the sake of clarity, a sectional view was selected in which two (of six) stator coils 310, 340 can be seen. The laminated core 400 is identical to the laminated core 400 shown in FIG. 1.

(32) As can be seen in FIG. 5, there is no surface that is oriented normal to the insertion direction E, E′ and that is situated within the total length GL of the laminated core and that does not intersect at least one of the protrusions 1, 3′. Thus, for example, a first surface FL1 runs without intersections through a first air gap SP1 that is situated between two corresponding protrusions 1, 6′. However, it is precisely this first surface that intersects another protrusion 4 of the first winding support 100.

(33) Consequently, each surface—here, for instance, the surfaces FL1, FL2—that is oriented normal to the insertion direction E and that is situated within the total length GL of the laminated core, intersects at least one of the protrusions 1, 3′.

(34) Finally, FIG. 6 shows a hand-held power tool 2000 with an electric motor 1000 into which—schematically depicted—a stator 500 according to the invention has been installed.

(35) An alternative embodiment is shown solely schematically in FIG. 7 in which three adjacent protrusions can have the same length. Precisely six protrusions 101, 102, 103, 104, 105, 106 are provided, whereby three adjacent protrusions 101, 102, 103 have the same length, then these three adjacent protrusions can form a semi-circle with long protrusions. Correspondingly, three adjacent protrusions 104, 105, 106 with the same, shorter length can form a semi-circle with short protrusions.

LIST OF REFERENCE NUMERALS

(36) 100, 100′ first, second winding support 110, 110′ connecting ring 1, 2, 3, 4, 5, 6 protrusions of the first winding support 1′, 2′, 3′, 4′, 5′ 6′ protrusions of the second winding support 10, 20, 30, 40, 50, 60 stator pole teeth 12, 23, 34, 45, 56, 61 cavity 101, 102, 103, 104, 105, 106 protrusions of an alternate embodiment 300, 310, 320, 330, 340 stator coil 400 laminated core 500 stator 1000 electric motor 2000 hand-held power tool E, E′ insertion direction EB thickness of the individual laminations FL0, FL1, FL2 surfaces GL total length of the laminated core K, K′ winding head SP, SP1, SP2, SP4 air gap U circumference UB overlapping area W angle