Electrical generator or motor structure – Dynamoelectric – Rotary
Reexamination Certificate
1999-06-21
2001-06-05
Ramirez, Nestor (Department: 2834)
Electrical generator or motor structure
Dynamoelectric
Rotary
C310S201000, C310S049540, C029S596000
Reexamination Certificate
active
06242836
ABSTRACT:
CROSS REFERENCE TO RELATED APPLICATION
The present application is based on and claims priority from Japanese Patent Application Hei 10-180755, filed on Jun. 26, 1998, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an ac generator's stator for a passenger car or a truck and a method of manufacturing the same.
2. Description of the Related Art
An insulating structure between a stator core and a stator winding of an ac generator's stator for a vehicle is disclosed in JP-A-8-80001, in which insulation film sheets are disposed between slot walls and the stator winding. Each slot has an opening formed at the inner periphery of the stator core, which is closed by a separate press-fitted wedge member to retain in-slot portions of the stator winding inside the slot.
Because the insulation film member and the press-fitted insulation member are separate in such a stator core, small gaps are necessarily formed between the two members. When a rotor rotates inside the stator, pressure near the slot openings rises. As a result, snow mixed with salt or salt water may be introduced into the slots through the small gaps by the cooling air blowing on the stator winding. This causes electrolyzation of the in-slot portions of the stator winding thereby resulting in insulation failure of the stator winding.
On the other hand, the space factor of the in-slot portions of the stator winding has been increased to satisfy recent demand for increasing output power of the vehicle ac generator. The separate wedge member has become an obstacle to increasing in the space factor.
SUMMARY OF THE INVENTION
Therefore, an object of the invention is to provide an ac generator's stator for a vehicle that has improved insulation structure formed between the stator winding and the stator core and a method of manufacturing such a stator.
In a stator of a vehicle ac generator according to a preferred embodiment of the invention, each of slot insulators has a closing portion closing the opening of slot. Therefore, electric conductors can be held within the slots without additional retaining members. In addition, the closing portion can shut out salt water or other electrolyte easily.
As a result, the insulation coating of the stator winding is free from damage otherwise caused by some of the wedge members being press-fitted into the slots.
Each of the insulators can be a roll of a rectangular sheet with opposite sides overlapping with each other to fit to the inner periphery of the slot. The insulators can be formed in a tubular fashion.
In a method of manufacturing the stator according to a preferred embodiment of the invention, a bundle of the in-slot portions is enclosed by an insulator sheet. Then, bundles of in-slot-portions are inserted into all the slots, and connecting portions extending from the bundles are connected to one another to form the stator winding.
Each of the insulators can be inserted into one of the slots and disposed to fit the entire peripheral surface of the slot and to close the opening of the slot before the conductors are inserted into the slot from one axial end of the stator core.
Thus, the ac generator's stator for a vehicle according to an embodiment of the invention can be manufactured easily.
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Ishida Hiroshi
Matsubara Shinichi
Denso Corporation
Mullins B
Pillsbury & Winthrop LLP
Ramirez Nestor
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