Cold Pressure Welding of Rectangular Coil Conductors
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Solution Overview
Problem
Existing methods for manufacturing rectangular coils face issues with heat dissipation performance and space factor due to rounded corners and insulating resin degradation, and cold pressure welding of rectangular conductors is challenging, leading to unstable connections.
Innovation Solution
A cold pressure welding apparatus with holding parts and a drive mechanism that moves to sandwich and weld flat conductors, using anti-slip surfaces and biasing members to ensure stable connections and improve space factor and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If rectangular conductors are wound to form coils, then space factor is improved, but corner portions become curved with rounded corners creating spaces around the core
Solution Approach 1:
The coil is divided into multiple rectangular conductor segments that are stacked and welded together. Each segment maintains sharp corners, and the segmentation allows the coil to fit tightly around the core without rounded corners creating spaces.
Solution Approach 2:
The coil uses composite construction with rectangular conductors having insulating resin coatings on specific surfaces. This composite structure allows sharp corners to be maintained while providing necessary insulation, resolving the conflict between space factor and corner shape.
2Shape
If rectangular conductors are stacked and welded, then corner sharpness is maintained, but welded portions have deteriorated characteristics
Solution Approach 1:
Insulating resin is applied selectively only on the outer peripheral surfaces of the rectangular conductors that require insulation, while the end surfaces to be welded remain exposed. This local differentiation maintains corner sharpness and welding quality by preventing resin interference at weld zones.
Solution Approach 2:
The insulating resin is extracted or removed from the end surfaces of the rectangular conductors at the welded portions. This extraction ensures that the welded joints have pure metal-to-metal contact without resin contamination, maintaining reliability while preserving corner sharpness.
3Object-affected harmful factors
If insulating resin coating is applied on rectangular conductors, then insulation is provided, but coating is reduced at outer peripheral corner portions due to bending
Solution Approach 1:
The insulating resin coating is applied locally only on the outer peripheral surfaces of the rectangular conductors, deliberately excluding the end surfaces. This local application prevents coating reduction issues at corners during bending while maintaining necessary insulation where the coil contacts itself.
Solution Approach 2:
The insulating resin is applied in advance on the outer peripheral surfaces before the conductors are bent into the coil shape. This preliminary action ensures proper insulation coverage on surfaces that will form the coil body, while the unbent end surfaces remain coating-free for welding.
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
The apparatus successfully welds rectangular conductors with improved stability and space factor, enhancing heat dissipation performance without characteristic deterioration.
Implementation Method 1
a cold pressure welding apparatus for welding flat plates together by causing the flat plates to be pressurized and deformed
Implementation Method 2
causing the flat plates to be pressurized and deformed
Implementation Method 3
biasing members to ensure stable connections
Implementation Method 4
using anti-slip surfaces and biasing members to ensure stable connections
Data Source
AI summary
The cold pressure welding apparatus includes a first holding part capable of sandwiching a first flat conductor, a second holding part disposed opposite to the first holding part and capable of sandwiching a second flat conductor, and a drive part for moving the first holding part and the second holding part. The drive part can move the first holding part and the second holding part between a first direction separated position and a close position along a first direction. The drive part can move the first holding part and the second holding part between a second direction separated position and a sandwiching position along a second direction.