Electrical generator or motor structure – Dynamoelectric – Rotary
Reexamination Certificate
1999-05-21
2001-03-27
Nguyen, Tran (Department: 2834)
Electrical generator or motor structure
Dynamoelectric
Rotary
C310S201000, C310S216006
Reexamination Certificate
active
06208060
ABSTRACT:
CROSS REFERENCE TO RELATED APPLICATION
The present application is based on and claims priority from Japanese Patent Applications Hei 10-143008 filed on May 26, 1998 and Hei 10-200554 filed on Jul. 15, 1998, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a stator of a vehicle ac generator driven by an internal combustion engine and a method of manufacturing the same.
2. Description of the Related Art
It is known that a plurality of conductor segments are welded to form a stator winding. WO92/06527 discloses a stator winding which is formed of a plurality of U-shaped conductor segments. The U-shaped conductor segments are inserted from an axial end of the stator core and connected to one another at portions thereof on the other end of the stator core, so that the stator can have regularly disposed coils more easily than the stator having a stator winding formed of continuously wound magnet wires.
Although WO92/06527 has no description about insulators disposed in the slots, such electric insulators are sometimes necessary under certain circumstances. If an insulator is formed of a plain insulating sheet, such an insulator may be dragged or shifted axially in a slot when a conductor segment is inserted into the slot covered by the insulator. As a result, bare surfaces of the stator can not be covered completely, and the conductor segments are not insulated well. If the insulators are fixed to the stator core by an adhesive agent or the like, additional steps and cost are necessary.
SUMMARY OF THE INVENTION
Therefore, the object of the invention is to provide a stator of a vehicle ac generator in which the insulators are prevented from moving to ensure good insulation performance.
According to a main feature of the invention, a stator core of an ac generator for vehicle is formed of a lamination of a plurality of steel sheets and a plurality of slots are cut out from the steel sheets in a cutout direction to provide burs projecting in the cutout direction. A plurality of deformable insulation sheets are inserted into the plurality of slots first, and a plurality of electric conductors are inserted into the plurality of slots in the direction opposite to the cutout direction. Because sharp edges of the burs are formed to extend in the cutout direction, insulators are impeded by sharp edges of the burs when the conductor segments are inserted into the slots in the direction opposite to the cutout direction. This ensures good insulation performance between the stator core and the conductor segments.
According to another feature of the invention, each of the electric conductors has a U-turn portion at the front end of the stator core in the cutout direction. Therefore, the insulators can be prevented from moving when the conductor segments are inserted.
According to another feature of the invention, each of the insulators has a folded lip disposed at the front end thereof in the cutout direction. The insulators can be surely prevented by the folded lips from shifting axially when the conductor segments are inserted. Each of the insulators can have the folded lip at the back end thereof in the slot-cutout direction. In this case, the folded lips protect the insulators from damage when coil ends are press-formed. When coil ends are formed, the insulators are pulled or pushed excessively between the conductor segments and the stator core. However, the folded lip prevents the insulator from being damaged.
According to another main feature of the invention, a method of manufacturing a stator core of a vehicle ac generator comprises a first step of forming a lamination of steel sheets, a second step of cutting a plurality of slots from the lamination in a cutout direction, a third step of inserting insulators into the slots, a fourth step of inserting conductor segments into the slots covered by the insulators in the direction opposite the cutout direction, and fifth step of connecting the conductor segments inserted into the slots to one another. Therefore, the insulators are held still by sharp edges of the burs when the conductor segments are inserted.
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Kusase Shin
Shiga Tsutomu
Umeda Atsushi
Denso Corporation
Nguyen Tran
Pillsbury & Winthrop LLP
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