I 1111111111111111 11111 lllll 111111111111111 111111111111111 IIIIII IIII IIII IIII
`US0083 84263B2
`
`c12) United States Patent
`Hiramatsu et al.
`
`(IO) Patent No.:
`(45) Date of Patent:
`
`US 8,384,263 B2
`Feb.26,2013
`
`(54) ROTATING ELECTRICAL MACHINE
`HAVING A COMPACT STATOR
`
`(75)
`
`Inventors: Hiromichi Hiramatsu, Yokohama (JP);
`Takashi Ishigami, Hitachinaka (JP);
`Yasuyuki Saito, Hitachinaka (JP);
`Yuichiro Tanaka, Hitachinaka (JP);
`Kenichi Nakayama, Hitachinaka (JP);
`Yutaka Matsunobu, Mita (JP); Noriaki
`Hino, Mita (JP)
`
`(73) Assignee: Hitachi, Ltd., Tokyo (JP)
`
`( *) Notice:
`
`Subject to any disclaimer, the term ofthis
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 156 days.
`
`(21) Appl. No.: 12/370,082
`
`(22) Filed:
`
`Feb.12,2009
`
`(65)
`
`Prior Publication Data
`
`US 2009/0267441 Al
`
`Oct. 29, 2009
`
`(30)
`
`Foreign Application Priority Data
`
`Feb. 14,2008
`Feb. 14,2008
`Feb. 14,2008
`
`(JP) ................................. 2008-032527
`(JP) ................................. 2008-032529
`(JP) ................................. 2008-032531
`
`(51)
`
`Int. Cl.
`H02K 3/28
`(2006.01)
`H02K 3/00
`(2006.01)
`H02K 3/04
`(2006.01)
`(52) U.S. Cl. ......................... 310/208; 310/195; 310/198
`(58) Field of Classification Search .................. 310/195,
`310/198,201,203,206,207,208, 179,180;
`H02K 3/00, 3/04, 3/12, 3/14, 3/28
`See application file for complete search history.
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`3,345,740 A *
`10/1967 Murdock et al ............... 310/206
`5,744,896 A *
`4/1998 Kessinger et al.
`............ 310/208
`6,359,361 Bl *
`3/2002 Wakui et al ................... 310/198
`6/2002 Nakamura et al.
`6,404,091 Bl
`2005/0200223 Al*
`9/2005 Tajima et al.
`............ 310/156.46
`2006/0066167 Al *
`3/2006 Saito et al. .................... 310/208
`2008/0174199 Al*
`7 /2008 Ishigami et al.
`.............. 310/206
`
`EP
`JP
`JP
`JP
`JP
`JP
`JP
`
`FOREIGN PATENT DOCUMENTS
`0 740 403 Al
`10/1996
`58-63054 A
`4/1983
`64-1444 A
`1/1989
`5-30693 A
`2/1993
`8-298756 A
`11/1996
`2000-350425 A
`12/2000
`2005-51981 A
`2/2006
`
`OTHER PUBLICATIONS
`
`Japanese Office Action dated Mar. 13, 2012 including English-lan(cid:173)
`guage translation (Five ( 5) pages).
`
`* cited by examiner
`
`Primary Examiner - Quyen Leung
`Assistant Examiner - Michael Andrews
`(74) Attorney, Agent, or Firm - Crowell & Moring LLP
`
`ABSTRACT
`(57)
`A rotating electrical machine includes a stator including at
`least two element coils of the same phase each having a
`plurality of turns and connected to each other through a coil(cid:173)
`to-coil connection wire, the element coils being arranged in
`adjacent slots, respectively; and a rotor rotatably provided to
`the stator through a gap. The element coils of the same phase
`are fitted in the adjacent slots so that wound around portions
`of the element coils partially overlap each other. The coil-to(cid:173)
`coil connection wire connects at a coil end portion conductor
`wires extending from linear conductor wire portions of inner(cid:173)
`most wires of the element coils contained in the slots.
`
`9 Claims, 66 Drawing Sheets
`
`4134
`
`4134
`
`4134
`
`4131
`U12
`
`4131b
`(SLOT 1)
`
`4131a
`(SLOT 2)
`
`4131b
`(SLOT 6)
`
`Ex.1008
`APPLE INC. / Page 1 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 1 of 66
`
`US 8,384,263 B2
`
`FIG.1
`
`412
`
`9
`
`7b
`
`6
`
`24
`
`Ex.1008
`APPLE INC. / Page 2 of 92
`
`

`

`U.S. Patent
`
`Feb. 26, 2013
`
`Sheet 2 of 66
`
`US 8,384,263 B2
`
`FIG.2
`
`530
`
`511
`
`5 ;
`
`512
`
`6
`
`Ex.1008
`APPLE INC. / Page 3 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 3 of 66
`
`US 8,384,263 B2
`
`LL
`
`Ex.1008
`APPLE INC. / Page 4 of 92
`
`

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`
`Ex.1008
`APPLE INC. / Page 5 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 5 of 66
`
`US 8,384,263 B2
`
`FIG.5
`
`430
`
`412
`
`5
`
`Ex.1008
`APPLE INC. / Page 6 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 6 of 66
`
`US 8,384,263 B2
`
`FIG.6
`
`411
`
`430
`
`Ex.1008
`APPLE INC. / Page 7 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 7 of 66
`
`US 8,384,263 B2
`
`FIG.7
`
`416
`
`4
`
`f
`
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`
`414
`
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`PORTION
`
`SLOT PORTION
`
`412
`
`COIL END
`PORTION
`
`Ex.1008
`APPLE INC. / Page 8 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 8 of 66
`
`US 8,384,263 B2
`
`FIG.8
`
`4134
`
`4134
`
`4134
`
`4131
`U12
`
`4131!
`U11
`
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`4131a
`(SLOT 7)
`4131 b
`(SLOT 6)
`
`4131a
`(SLOT 2)
`
`4131b
`(SLOT 1)
`
`Ex.1008
`APPLE INC. / Page 9 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 9 of 66
`
`US 8,384,263 B2
`
`FIG.9
`
`4132
`
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`(SLOT 43)
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`(SLOT 2)
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`(SLOT 1)
`
`4131a
`(SLOT 44)
`
`Ex.1008
`APPLE INC. / Page 10 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 10 of 66
`
`US 8,384,263 B2
`
`FIG.10
`
`412
`
`414
`
`4
`~
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`4132
`
`4132a
`
`Ex.1008
`APPLE INC. / Page 11 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 11 of 66
`
`US 8,384,263 B2
`
`FIG.11
`
`4132
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`COIL END
`PORTION
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`
`Ex.1008
`APPLE INC. / Page 12 of 92
`
`

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`
`3 3 3 3
`w w V V
`
`~~
`
`2 2 2 2
`w w V V
`
`~ ~
`
`, , , ,
`w w V V
`
`~ ~
`
`8 8 8 8
`w w V V
`
`~ ~
`
`7 7 7 7
`w w V V
`
`@ @
`
`6 6 6 6
`w w V V
`
`24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23
`
`FIG.13
`
`Ex.1008
`APPLE INC. / Page 14 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 14 of 66
`
`US 8,384,263 B2
`
`FIG.14
`
`WIND COIL AROUND CORE
`
`(PREFORMING STEP)
`
`PREFORM COIL BY PRESSURE FORMING
`
`(PREFORMING STEP)
`
`FIT LINEAR REGION ON OUTER CIRCUMFERENCE SIDE OF
`PREFORMED COIL IN SLOT
`(ARRANGING STEP)
`
`INNER CIRCUMFERENCE SIDE OF COIL
`INSERT LINEAR REGION ON
`INTO OPEN GROOVE ON OUTER CIRCUMFERENCE OF INNER JIG
`
`ATTACH SUPPORT JIG AND TEETH SUPPORT JIG
`
`ATTACH PRESS JIG
`
`INNER JIG
`FORM HEXAGONAL COIL BY ROTATING
`FORM I NG STEP)
`
`(TEMPORARY
`
`INNER CIRCUMFERENCE SIDE OF COIL
`INSERT LINEAR REGION ON
`INTO SLOT (INSERTING STEP)
`
`111
`
`112
`
`116
`
`117
`
`118
`
`INNER JIG
`REMOVE
`~ - - - - - - - - - , - - - - - - - - - -~ 120
`
`CONNECT WIRE CONNECTION PART
`
`ASSEMBLE ROTOR
`
`IN STATOR
`
`(ASSEMBLING STEP)
`
`Ex.1008
`APPLE INC. / Page 15 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 15 of 66
`
`US 8,384,263 B2
`
`FIG.15A
`
`FIG.158
`
`14
`
`4131b
`
`4131a
`
`~14
`
`) )
`
`4131a 4131b
`
`Ex.1008
`APPLE INC. / Page 16 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 16 of 66
`
`US 8,384,263 B2
`
`14
`
`FIG.16
`
`413
`
`Ex.1008
`APPLE INC. / Page 17 of 92
`
`

`

`U.S. Patent
`
`Feb. 26, 2013
`
`Sheet 17 of 66
`
`US 8,384,263 B2
`
`FIG.17
`
`4132
`
`4133
`
`--4131b
`
`Ex.1008
`APPLE INC. / Page 18 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 18 of 66
`
`US 8,384,263 B2
`
`FIG.18A
`
`17
`
`FIG.18B
`
`171
`
`4133
`
`4133
`
`__,__4133
`
`18
`
`413
`
`4133
`
`18
`
`Ex.1008
`APPLE INC. / Page 19 of 92
`
`

`

`U.S. Patent
`
`Feb. 26, 2013
`
`Sheet 19 of 66
`
`US 8,384,263 B2
`
`FIG.19
`
`4133b
`
`4131
`
`4133a
`
`Ex.1008
`APPLE INC. / Page 20 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 20 of 66
`
`US 8,384,263 B2
`
`FIG.20
`
`19
`
`~
`
`194
`
`193
`
`191
`
`Ex.1008
`APPLE INC. / Page 21 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 21 of 66
`
`US 8,384,263 B2
`
`FIG.21
`
`19
`
`192-----
`
`194
`
`193
`
`191
`
`Ex.1008
`APPLE INC. / Page 22 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 22 of 66
`
`US 8,384,263 B2
`
`FIG.22
`
`4133b
`
`Ex.1008
`APPLE INC. / Page 23 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 23 of 66
`
`US 8,384,263 B2
`
`FIG.23A
`
`FIG.23B
`
`i9
`
`4131
`
`Ex.1008
`APPLE INC. / Page 24 of 92
`
`

`

`U.S. Patent
`
`Feb. 26, 2013
`
`Sheet 24 of 66
`
`US 8,384,263 B2
`
`FIG.24
`
`231---
`
`412
`
`23
`
`,-J23a
`
`4131
`
`23b
`
`Ex.1008
`APPLE INC. / Page 25 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 25 of 66
`
`US 8,384,263 B2
`
`FIG.25
`
`20
`
`19
`
`4131
`
`412
`
`Ex.1008
`APPLE INC. / Page 26 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 26 of 66
`
`US 8,384,263 B2
`
`FIG.26
`
`411----- Ill
`..
`
`418
`
`t
`
`BEFORE INSERTION
`
`AFTER INSERTION
`
`...
`
`418
`
`Ex.1008
`APPLE INC. / Page 27 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 27 of 66
`
`US 8,384,263 B2
`
`FIG.27
`
`416
`
`4131
`
`Ex.1008
`APPLE INC. / Page 28 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 28 of 66
`
`US 8,384,263 B2
`
`FIG.28
`
`4131
`
`418
`
`FIG.29
`414
`
`412
`
`417
`
`Ex.1008
`APPLE INC. / Page 29 of 92
`
`

`

`U.S. Patent
`
`Feb. 26, 2013
`
`Sheet 29 of 66
`
`US 8,384,263 B2
`
`FIG.30
`
`4134
`
`413
`
`4133
`
`4131b
`
`4133 ---
`
`4133----· . .-
`
`Ex.1008
`APPLE INC. / Page 30 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 30 of 66
`
`US 8,384,263 B2
`
`FIG.31 A
`
`FIG.31 B
`
`4132
`
`413
`
`25
`
`251
`
`~
`
`254
`
`4134
`
`255
`
`254
`
`25 j
`
`251
`
`413
`
`4132
`
`Ex.1008
`APPLE INC. / Page 31 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 31 of 66
`
`US 8,384,263 B2
`
`FIG.32
`
`413 j
`
`4131a
`
`4131b
`
`Ex.1008
`APPLE INC. / Page 32 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 32 of 66
`
`US 8,384,263 B2
`
`FIG.33
`
`FIT FORMED COIL BODY THAT HAS BEEN PREFORMED AND
`INTO SLIDE JIG
`INSULATION PAPER
`PROVIDED WITH
`(ARRANGING STEP)
`
`FORM HEXAGONAL COIL BY SLIDING JIG ON MOVING SIDE
`(TEMPORARY FORMING STEP)
`
`BENDING LINEAR REGION ON ONE SIDE OF HEXAGONAL COIL TO
`(TEMPORARY FORMING STEP)
`PREDETERMINED ANGLE
`
`INNER CIRCUMFERENCE SIDE
`FIT HEXAGONAL COIL TO MEMBER ON
`(TEMPORARY FORMING STEP)
`
`INSERT LINEAR REGION OF COIL INTO SLOT (INSERTING STEP)
`
`TAKE OUT
`
`INNER MEMBER
`
`221
`
`222
`
`223
`
`224
`
`226
`
`Ex.1008
`APPLE INC. / Page 33 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 33 of 66
`
`US 8,384,263 B2
`
`FIG.34
`
`4131
`
`35b
`
`35
`
`Ex.1008
`APPLE INC. / Page 34 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 34 of 66
`
`US 8,384,263 B2
`
`FIG.35
`
`4131
`
`4132
`
`LONGITUDINAL DIRECTION
`
`VV I~ . ~ r
`
`35
`
`35a
`
`Ex.1008
`APPLE INC. / Page 35 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 35 of 66
`
`US 8,384,263 B2
`
`FIG.36
`
`35a
`
`351
`
`--353
`
`-------351
`
`353
`
`Ex.1008
`APPLE INC. / Page 36 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 36 of 66
`
`US 8,384,263 B2
`
`FIG.37
`
`35a
`
`351
`
`353
`-351
`
`35b
`
`353
`
`Ex.1008
`APPLE INC. / Page 37 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 37 of 66
`
`US 8,384,263 B2
`
`FIG.38
`
`361
`
`413
`
`4131
`
`Ex.1008
`APPLE INC. / Page 38 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 38 of 66
`
`US 8,384,263 B2
`
`FIG.39
`
`411
`
`36
`
`364
`
`413
`
`412
`
`Ex.1008
`APPLE INC. / Page 39 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 39 of 66
`
`US 8,384,263 B2
`
`FIG.40A
`
`364
`
`41
`
`412
`
`FIG.40C
`
`Ex.1008
`APPLE INC. / Page 40 of 92
`
`

`

`U.S. Patent
`
`Feb. 26, 2013
`
`Sheet 40 of 66
`
`US 8,384,263 B2
`
`FIG.41
`
`36
`
`413
`
`412
`
`Ex.1008
`APPLE INC. / Page 41 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 41 of 66
`
`US 8,384,263 B2
`
`.
`C)
`LL
`
`Ex.1008
`APPLE INC. / Page 42 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 42 of 66
`
`US 8,384,263 B2
`
`FIG.43
`
`4131a
`
`4131b
`
`4132
`
`412
`
`--4131
`
`Ex.1008
`APPLE INC. / Page 43 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 43 of 66
`
`US 8,384,263 B2
`
`FIG.44
`
`;---4
`
`Ex.1008
`APPLE INC. / Page 44 of 92
`
`

`

`U.S. Patent
`
`Feb. 26, 2013
`
`Sheet 44 of 66
`
`US 8,384,263 B2
`
`FIG.45
`
`r:.200
`
`212
`
`230
`232 rA
`
`I
`
`218
`
`•
`l....A
`
`254
`
`252
`
`224 226
`
`Ex.1008
`APPLE INC. / Page 45 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 45 of 66
`
`US 8,384,263 B2
`
`FIG.46
`
`290
`
`280
`
`290
`~===--+ 252
`
`,r.;;;;;:;;__.;.;...-r--..202
`
`·-t---280
`
`290
`
`284
`
`Ex.1008
`APPLE INC. / Page 46 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 46 of 66
`
`US 8,384,263 B2
`
`FIG.47
`
`94
`
`413
`
`412
`
`Ex.1008
`APPLE INC. / Page 47 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 47 of 66
`
`US 8,384,263 B2
`
`FIG.48
`
`4131b
`
`4131a
`
`94
`
`94
`
`4131aX
`
`4131bX
`
`4135a
`
`4131bY
`
`90
`
`I
`l
`I
`
`I >i .
`
`Ex.1008
`APPLE INC. / Page 48 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 48 of 66
`
`US 8,384,263 B2
`
`FIG.49
`
`92
`
`94
`
`94
`
`412
`
`Ex.1008
`APPLE INC. / Page 49 of 92
`
`

`

`U.S. Patent
`
`Feb. 26, 2013
`
`Sheet 49 of 66
`
`US 8,384,263 B2
`
`FIG.SO
`
`4134
`
`952
`
`952
`
`951
`
`Ex.1008
`APPLE INC. / Page 50 of 92
`
`

`

`U.S. Patent
`
`Feb. 26, 2013
`
`Sheet 50 of 66
`
`US 8,384,263 B2
`
`FIG.51
`
`4131a
`
`4134
`
`4131b
`
`....
`...
`.....
`
`,,_. . ..
`.. .
`
`Ex.1008
`APPLE INC. / Page 51 of 92
`
`

`

`U.S. P a t e n t
`U.S. Patent
`Feb. 26, 2013
`Feb. 26, 2013
`FIG.52
`FIG.52
`
`Sheet 51 o f 66
`Sheet 51 of 66
`
`US 8,384,263 B2
`US 8,384,263 B2
`
`4134
`
`ors
`
`it=iGateed
`
`rainsrsetoosbatartgtetoanyen
`neMeteaenegroac
`eeeepm
`
`90
`
`90
`
`
`
`Ex.1008
`APPLEINC./ Page 52 of 92
`
`Ex.1008
`APPLE INC. / Page 52 of 92
`
`
`

`

`U.S. Patent
`
`Feb. 26, 2013
`
`Sheet 52 of 66
`
`US 8,384,263 B2
`
`FIG.53
`
`4134
`
`4131b
`
`Ex.1008
`APPLE INC. / Page 53 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 53 of 66
`
`US 8,384,263 B2
`
`FIG.54
`
`4132
`
`4132
`
`91
`
`4133
`
`Ex.1008
`APPLE INC. / Page 54 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 54 of 66
`
`US 8,384,263 B2
`
`FIG.55
`
`e
`
`91
`
`91
`
`413
`
`Ex.1008
`APPLE INC. / Page 55 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 55 of 66
`
`US 8,384,263 B2
`
`0
`0)
`
`0
`0)
`
`I
`0 "' , -
`
`(0
`LO
`0
`LL
`
`Ex.1008
`APPLE INC. / Page 56 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 56 of 66
`
`US 8,384,263 B2
`
`FIG.57
`
`90
`
`413
`
`120
`✓ ~
`
`411
`
`B
`
`90
`
`413
`
`Ex.1008
`APPLE INC. / Page 57 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 57 of 66
`
`US 8,384,263 B2
`
`FIG.58
`
`150
`
`150
`
`90
`
`Ex.1008
`APPLE INC. / Page 58 of 92
`
`

`

`U.S. Patent
`
`Feb. 26, 2013
`
`Sheet 58 of 66
`
`US 8,384,263 B2
`
`FIG.59
`
`140
`
`120/
`
`120
`
`130
`
`~
`
`: :::
`
`'
`
`140
`
`"'-120
`
`413
`
`Ex.1008
`APPLE INC. / Page 59 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 59 of 66
`
`US 8,384,263 B2
`
`FIG.60
`
`413
`
`160--
`
`Ex.1008
`APPLE INC. / Page 60 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 60 of 66
`
`US 8,384,263 B2
`
`421 }
`421
`421
`
`4131
`
`FIG.61A
`
`4221
`
`414
`
`421
`
`422
`
`414
`
`4221
`
`417
`
`FIG.61 B
`
`4221
`
`4227
`
`411
`
`Ex.1008
`APPLE INC. / Page 61 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 61 of 66
`
`US 8,384,263 B2
`
`FIG.62
`
`423
`
`4131
`
`423
`
`422
`
`Ex.1008
`APPLE INC. / Page 62 of 92
`
`

`

`U.S. Patent
`
`Feb. 26, 2013
`
`Sheet 62 of 66
`
`US 8,384,263 B2
`
`FIG.63A
`
`FIG.638
`
`FIG.63C
`
`FIG.63D
`
`FIG.63E
`
`FIG.63F
`
`4221
`
`16
`
`Ex.1008
`APPLE INC. / Page 63 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 63 of 66
`
`US 8,384,263 B2
`
`421
`
`422
`
`4 . . . ., . . .
`t
`t
`.M ~ •
`
`•
`
`a
`
`t
`
`lit'
`
`,,i:
`
`--
`
`FIG.64
`
`OUTER CIRCUMFERENCE
`SIDE OF STATOR
`
`INNER CIRCUMFERENCE
`SIDE OF STATOR
`
`•
`
`"
`
`ll-
`
`T
`
`/IC . . . ,IC
`II ¥
`•
`.-
`II
`.. "'II :,p
`.. (cid:127)
`IC &
`
`I
`
`(cid:127)
`
`.-C .. I
`
`f'
`
`l'l'~ .. :1o ... • .. 1J,r'f',.
`
`. . . . . . . . 11
`..
`..
`..
`<iJ 1;
`ti:
`-4,
`"II'
`•
`,,. . . .
`.. ~ C: ~ ~
`... "
`"
`Jr
`
`4221
`
`411
`
`414
`
`...... " ,.
`. . .. .. .
`..... .,., ....
`"' ~ .,_ 1'
`...
`.. ;II
`•
`t
`1'
`"
`•
`it
`...
`" ~ "- ....
`:a
`... . . ~ "' ..
`,a
`L
`21'
`' 1' "'
`.,.
`•
`..
`~ ff .. .,,
`,..
`...
`• <
`•
`,. •
`II
`,-
`•
`fl
`It.,,,_." ..
`.., ,. .. " ~
`.......
`,. ......... ,,
`. ""."" ..... ,. ",/",,
`:'":":":":"':
`,,, .... .-M .. ff•• o'C il.,.. __ "f ____ .....,
`
`..,.
`
`4
`
`,..
`
`.,., "'
`
`..
`
`(cid:127)
`
`fl
`1' a, M ~ .,_,
`... "'
`II-
`•
`:,p
`._
`•
`C
`._
`:lo
`. . . . . . . . . ,II
`
`Ex.1008
`APPLE INC. / Page 64 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 64 of 66
`
`US 8,384,263 B2
`
`FIG.65A
`
`FIG.65B
`
`4131
`
`422
`
`4221
`
`.. ·»· . ~ • . . . . ~
`
`.~ .
`
`16
`
`Ex.1008
`APPLE INC. / Page 65 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 65 of 66
`
`US 8,384,263 B2
`
`421 FIG.66A
`
`FIG.66B
`
`422
`
`4221
`
`Ex.1008
`APPLE INC. / Page 66 of 92
`
`

`

`U.S. Patent
`
`Feb.26,2013
`
`Sheet 66 of 66
`
`US 8,384,263 B2
`
`FIG.67A
`
`FIG.67B
`
`414
`
`414
`
`INNER
`CIRCUM(cid:173)
`FERENCE
`SIDE OF
`STATOR
`
`411
`
`D
`
`421
`
`SI DE OF STATOR :::::::::::
`· .. · .. ·.·.·.·
`
`::/::;:
`.•.:,.-.•.·
`
`D 411
`
`422
`
`4221
`
`4221
`
`Ex.1008
`APPLE INC. / Page 67 of 92
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`

`

`US 8,384,263 B2
`
`1
`ROTATING ELECTRICAL MACHINE
`HAVING A COMPACT STATOR
`
`INCORPORATION BY REFERENCE
`
`5
`
`The disclosures of the following priority applications are
`herein incorporated by reference:
`Japanese Patent Application No. 2008-032529 filed Feb.
`14,2008
`Japanese Patent Application No. 2008-032527 filed Feb. 10
`14,2008
`Japanese Patent Application No. 2008-032531 filed Feb.
`14,2008
`
`BACKGROUND OF THE INVENTION
`
`15
`
`2
`insulation into a slot of the stator. This delimits the space
`factor and heat dissipation performance of the coil.
`In the case of inserting a coil into a slot of a rotating
`electrical machine, it is desirable that a coil in whole has a
`flexibility upon deformation of the coil into a shape suitable
`for inserting it into the slot after having been formed into a
`wound shape. However, when the coil is inserted into the slot
`after the deformation, it is necessary to fix the slot insertion
`region of the coil so that it will not loosen or feaze. The
`conventional technology would not have sufficiently taken
`account of achieving a good balance between the two prop-
`erties.
`
`SUMMARY OF THE INVENTION
`
`1. Field of the Invention
`to rotating electrical
`The present invention relates
`machines such as electric motors and generators.
`2. Description of Related Art
`The tightening regulations on the exhaust gas emission to
`cope with soaring oil prices and global warming have acti(cid:173)
`vated development of electric vehicles and hybrid electric
`vehicles that use rotating electrical machines such as motors
`and generators.
`Conventional distributed winding stators for these rotating
`electrical machines include those stators of a lap winding
`format as disclosed in, for example, JP H08-298756A and JP
`2005-51981A. Such a lap winding stator is constituted as
`follows. A rectangular wire is wound into individual oblong
`coin-like coils (i.e., ellipse-like coils having two parallel lin(cid:173)
`ear sides bridged by round ends; hereafter referred to as
`ellipse-like coils). Each of the ellipse-like coils is fixed in
`whole and the fixed wires are subjected to torsional deforma- 35
`tion. The coil ends of each coil are formed into a non-inter(cid:173)
`fering format for double layer winding. The individual coils
`thus obtained are inserted in respective slots to provide a lap
`winding stator.
`A coil for use in a rotating electric machine in the related art 40
`is disclosed in, for example, JP S64-1444A. The coil is
`formed as follows. That is, a temporary fixation tape is wound
`around an original form coil having a pair of linear regions
`thereof that are to constitute coil sides of a final coil using a
`film insulator composed of a wound thermoplastic film. Then, 45
`only the linear regions of the original form coil is introduced
`into an ultrasonic welding apparatus equipped with a fixing
`apparatus to weld the insulator film of the wire and an insu(cid:173)
`lation tape for insulation from ground is wound. The thus
`insulated coil is then inserted into a slot.
`The conventional distributed winding stator, however, is
`manufactured by winding and deforming coils one by one.
`This makes it necessary to provide wire terminals twice the
`number of the coils and arrange and weld the wire terminals
`onto the side or top part of the coil ends. This results in an
`increase in the size of the coil ends, so that it has been difficult
`to provide compact connection and arrangement of the wire
`terminals.
`Two slot insertion regions of the lap winding coil that are to
`be inserted into slots are arranged in different slots of the 60
`stator, so that they could not be inserted the slots without
`undergoing elastic deformation. When the lap winding coils
`are continuously formed, the coils pull each other, resulting in
`an increase in difficulty of the operation of inserting the coils
`into the slots. For these reasons, a certain gap (0.1 to 0.2 mm 65
`or more) is required between the two coils in order to
`assemble a continuous lap winding coil of a flat wire with
`
`It is an object of the present invention to provide a rotating
`electrical machine that can improve the space factor and
`radiation performance, achieve size reduction and higher out-
`20 put power, and improve productivity.
`To achieve the above-mentioned object, the present inven(cid:173)
`tion provides a rotating electrical machine that comprises a
`stator including at least two element coils of the same phase
`each having a plurality of turns and connected to each other
`25 through a coil-to-coil connection wire, the element coils
`being arranged in adjacent slots, respectively; and a rotor
`rotatably provided to the stator through a gap, wherein: the
`element coils of the same phase are fitted in the adjacent slots
`so that wound around portions of the element coils partially
`30 overlap each other; and the coil-to-coil connection wire con(cid:173)
`nects at a coil end portion conductor wires extending from
`linear conductor wire portions of innermost wires of the ele(cid:173)
`ment coils contained in the slots.
`A rotating electrical machine according to another embodi-
`ment includes: a stator having incorporated there in a plurality
`of double-layer lap winding coils connected to each other
`through a bridge wire, with wire of each coil having a sub(cid:173)
`stantially rectangular shape; and a rotor rotatably provided to
`the stator through a gap, wherein slots in the stator are each
`provided with an outwardly extending inclination on an inner
`circumference side of an insertion portion where the coil and
`an insulation are to be inserted.
`A rotating electrical machine according to another embodi(cid:173)
`ment includes: a stator including a stator core in which a
`plurality of slots are formed in a circumferential direction,
`each of the slots being provided with a coil insertion portion
`on an inner circumference thereof, and a coil that is formed by
`winding around a stator winding wire a plurality of times; and
`50 a rotor rotatably provided on an inner circumference side of
`the stator, wherein the coil is bundled by being wrapped with
`an insulator, a portion of the coil that is wrapped with the
`insulator is inserted into the slot in a radial direction, and a
`coil end portion of the coil is not wrapped with the insulator
`55 so that the coil is left to be exposed.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is a sectional side view showing an electrical motor;
`FIG. 2 is a perspective view showing the cross-section of a
`rotor;
`FIG. 3 is an exploded perspective view showing respective
`parts of a motor;
`FIG. 4 is a system diagram illustrating electrical connec(cid:173)
`tions;
`FIG. 5 is a diagram showing the conditions of rotating
`magnetic fields generated by stator windings;
`
`Ex.1008
`APPLE INC. / Page 68 of 92
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`

`US 8,384,263 B2
`
`3
`FIG. 6 is a diagram showing the condition of magnetic
`fluxes when the rotation speed of the rotor is lower than the
`rotation speed of the rotating magnetic fields generated by the
`stator core;
`FIG. 7 is a perspective view of a stator;
`FIG. 8 is perspective view of a single continuous coil for
`constituting a stator winding;
`FIG. 9 is a perspective view showing a coil for a given
`phase;
`FIG. 10 is a front view of a stator;
`FIG. 11 is a side view of a stator;
`FIG. 12 is a connection wiring diagram of a stator winding;
`FIG. 13 is a diagram showing the relationship between slot
`numbers of the stator and the respective coils constituting the 15
`stator windings;
`FIG. 14 is a flowchart showing a manufacturing process;
`FIG. 15A is a diagram illustrating a method of forming an
`ellipse-like coil;
`FIG. 15B is an enlarged view of the part indicated by a 20
`symbol (B) in FIG. 15A;
`FIG. 16 is a perspective view in a state where the ellipse(cid:173)
`like coil is compression formed
`FIG. 17 is a perspective view of a preformed coil;
`FIG. 18A is a diagram showing an example of the forming 25
`using a punch and a die;
`FIG. 18B is a diagram showing an alternative example of
`the forming using a punch and a die;
`FIG. 19 is a perspective view showing a state in which the
`preformed coil is fitted in a slot of the stator core;
`FIG. 20 is a perspective view illustrating a state in which
`the pushing part of an inner jig is retracted;
`FIG. 21 is a perspective view illustrating a state in which
`the pushing part of the inner jig used in the first embodiment 35
`is protruded;
`FIG. 22 is a sectional perspective view of a state in which
`the top part (in the figure) of the stator core fitted with a teeth
`support jig has been cut off;
`FIG. 23A is a diagram a state in which the preformed coil 40
`is fitted in a slot of the stator core, and an inner jig and a
`support jig are fitted;
`FIG. 23B is diagram showing main parts in detail;
`FIG. 24 is a partial sectional perspective view showing a
`state in which a pressing jig is fitted;
`FIG. 25 is a perspective view of the stator having subjected
`to temporary forming;
`FIG. 26 is a diagram showing deformation of a wound
`around portion of a coil in an insertion step;
`FIG. 27 is a perspective view showing a state in which the 50
`coil is inserted in a slot of the stator;
`FIG. 28 is a perspective view showing the coil end of the
`stator in an enlarged view;
`FIG. 29 is a front sectional view of the stator;
`FIG. 30 is a simplified view of paired windings of the 55
`wound around portion in the coil of a fifth embodiment;
`FIG. 31A is a diagram illustrating a method of preforming
`according to the fifth embodiment;
`FIG. 31B is a diagram seen from A-A side of FIG. 31A;
`FIG. 32 is a perspective view of the coil formed by the 60
`preforming method according to the fifth embodiment;
`FIG. 33 is a flowchart illustrating manufacturing process
`from the arranging step to the inserting step, which are the
`features of a sixth embodiment;
`FIG. 34 is a perspective view illustrating a state in which 65
`the coil is arranged on a sliding jig used in the sixth embodi-
`ment;
`
`4
`FIG. 35 is a perspective view illustrating a state in which
`the slidingjig used in the sixth embodiment is slid to form the
`wound around portions of the coils into substantially hexago(cid:173)
`nal shapes;
`FIG. 36 is an enlarged perspective view showing fixation
`grooves of the sliding jig used in the sixth embodiment;
`FIG. 37 is a perspective view showing a state in which
`grooves in one of the halves of the jig in FIG. 36 are slanted;
`FIG. 38 is a perspective view showing a state in which the
`10 substantially hexagonal formed coils are wound around the
`inner jig in the sixth embodiment;
`FIG. 39 is a perspective view showing a state in which the
`inner jig with the coils fitted therearound is placed into the
`stator core;
`FIG. 40A is a perspective view showing a state in which the
`insertion step in the sixth embodiment has been performed;
`FIG. 40B is a diagram showing a state in which the extrud(cid:173)
`ing member is retracted from the slit in the insertion step;
`FIG. 40C is a diagram showing a state in which the extrud(cid:173)
`ing member is protruding from the slit in the insertion step in
`the sixth embodiment;
`FIG. 41 is a perspective view showing a state in which the
`inner jig is being withdrawn in the sixth embodiment;
`FIG. 42 is a diagram showing how to connect a bridge wire
`that couples the coils in a seventh embodiment;
`FIG. 43 is a perspective view showing a stator according to
`an eighth embodiment;
`FIG. 44 is a perspective view showing a stator according to
`a ninth embodiment;
`FIG. 45 is a cross-sectional view showing a permanent
`magnet rotating electrical machine;
`FIG. 46 is an A-Across-section showing the stator and the
`rotor shown in FIG. 45;
`FIG. 47 is a diagram showing the stator in the first embodi(cid:173)
`ment;
`FIG. 48 is a diagram showing two connected lap winding
`coils in a row;
`FIG. 49 is a diagram show in the coil end