Cold-Pressure Welded Coil Unit for Compact Stator Assembly

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Solution Overview

Problem

Conventional methods for connecting coils in stators, such as welding or screwing, result in complex configurations that limit downsizing and complicate manufacturing processes, leading to oversized apparatuses and intricate operations.

Innovation Solution

A coil unit is created using cold pressure welding, where the coil and bus bar connection ends are butt-jointed in a helical structure, allowing for a minimized welded portion that simplifies the configuration and reduces the size of the stator, while also enabling simplified manufacturing steps by integrating the coil and bus bar with an insulating resin.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional welding or screwing methods are used to connect coils to bus bars, then the connection is achieved, but the configuration becomes complicated and the stator size increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidconnection configuration complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention extracts the connection point from the traditional end-position location and relocates it to the intermediate position along the coil width direction. This extraction allows the connection to be made at a more convenient location that simplifies the overall configuration while maintaining connection reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of connecting the coil ends at the traditional position (end of the coil in the width direction), the invention inverts the connection approach by connecting at the intermediate position. This inversion of the connection location fundamentally simplifies the configuration and enables downsizing of the stator.

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If conventional welding or screwing methods are used to connect coils to bus bars, then the connection is achieved, but the apparatus size increases and operations become complicated

Engineering Contradiction:

Improveconnection reliabilityVSAvoidconnection operation simplicity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The invention extracts the connection operation from the complex traditional process by relocating the connection point to the intermediate position. This extraction simplifies the operation as the connection can now be made at a more accessible and convenient location, reducing operational complexity.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention inverts the conventional connection approach by connecting at the intermediate position rather than at the end position. This inversion makes the connection operation simpler and more accessible, thereby improving ease of operation while maintaining connection reliability.

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of manufacture

If coils are annularly disposed and connected to circular bus bars, then the stator can be assembled, but the welded portion has a complicated configuration that limits downsizing

Engineering Contradiction:

Improvestator assembly feasibilityVSAvoidstator size

Core Design Contradiction:

Ease of manufactureVSVolume of moving object

Solution Approach 1:

The invention extracts the connection point from the traditional end-position location and relocates it to the intermediate position along the coil width direction. This extraction allows for a more compact configuration that enables downsizing of the stator while maintaining assembly feasibility.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of connecting at the traditional end position, the invention inverts the connection approach by connecting at the intermediate position. This inversion enables a more compact stator configuration, achieving downsizing while maintaining ease of manufacture.

Inventive Principle:

Principle #13The other way round (Inversion)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enables downsizing of the coil unit and stator, simplifies the manufacturing process, and improves the uniformity of the insulating resin coating, enhancing the structural integrity and reducing operational complexity.

Implementation Method 1

One end of the coil and the connection end portion are welded by cold pressure welding with end faces of them being butted in a welded portion

Methodology Applied

Scientific EffectCold pressure welding: Diffusion Welding

Data Source

PatentUS12199483B2Coil unit, stator member, stator, motor, and manufacturing method for coil unit, stator member, stator, and motor

Publication Date: 2025.01.14 ASTER CO LTD

AI summary

There are provided a coil unit, a stator member, a motor, and methods of manufacturing these, configured to achieve downsizing and simplified manufacturing steps. The coil unit includes a coil, and a bus bar including a connection end portion to which the coil is connected. One end of the coil and the connection end portion are welded by cold pressure welding with end faces of them being butted in a welded portion.