Partially Stripped Motor Conductor for Clean Laser Welding

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Solution Overview

Problem

Existing methods for removing the insulating coating layer from electrical conductors in rotary electric machines are time-consuming, generate dust and residue, and pose risks of burning or electrical short circuits during laser welding.

Innovation Solution

A method involving a partially bared electrical conductor with distinct portions - a main, intermediate, and bared portion - allows for optimized laser baring with reduced dust and residue, ensuring effective welding without damaging the coating layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If mechanical removal method (blade or abrasive means) is used to remove coating layer, then coating layer is removed, but cycle time is long and dust/residue is generated

Engineering Contradiction:

Improvedust and residue generationVSAvoidcycle time

Core Design Contradiction:

Loss of substanceVSLoss of time

Solution Approach 1:

The patent replaces mechanical removal methods (blade or abrasive means) with laser removal technology. The laser beam selectively removes the insulating coating layer without generating dust or residue, and the process is highly efficient with short cycle time. This substitution of mechanical system with optical/thermal system resolves the contradiction between minimizing substance loss and reducing time loss.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If coating layer is completely removed for welding, then welding can be performed, but risk of electrical short circuit increases

Engineering Contradiction:

Improveelectrical short circuit riskVSAvoidwelding preparation

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies local quality by creating different surface conditions in different regions of the conductor. The end portion has the coating layer completely removed to enable welding, while the main body retains the insulating coating layer to prevent electrical short circuits. This localized differentiation of surface properties resolves the contradiction between ensuring welding capability and preventing electrical shorts.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The conductor is segmented into two functional zones: a bared end portion for welding and a coated main body for insulation. This segmentation allows each portion to serve its specific function optimally, with the end portion prepared for reliable welding while the main body maintains electrical insulation, thus resolving the contradiction between welding ease and short circuit prevention.

Inventive Principle:

Principle #1Segmentation

3Productivity

If laser baring is used to remove coating layer, then cycle time is optimized and dust is minimized, but complete removal may be difficult to achieve

Engineering Contradiction:

Improvecycle timeVSAvoidcoating layer removal completeness

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies partial action by removing the coating layer only from the end portion of the conductor rather than the entire surface. This selective partial removal achieves the necessary welding preparation while maintaining insulation on the main body, and the laser process efficiently accomplishes this partial removal with complete precision and minimal dust generation, resolving the contradiction between productivity and manufacturing precision.

Inventive Principle:

Principle #16Partial or excessive action

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 method reduces cycle time, minimizes dust generation, and prevents electrical short circuits while maintaining the integrity of the insulating coating, enhancing the efficiency and reliability of the welding process.

Implementation Method 1

a first step of baring the intermediate portion and the bared portion, said step being performed with a first laser beam having a first wavelength, and a second step of baring only the bared portion, said step being performed with a second laser beam having a second wavelength

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS12609514B2Electrical conductor for a rotating electrical machine wound component

Publication Date: 2026.04.21 VALEO EQUIP ELECTRIC MOTEUR

AI summary

An electrical conductor for a rotating electrical machine wound component includes a body formed of an electrically conductive material and a coating layer formed of an electrically insulating material, the coating layer partially covering the body. The conductor is formed of a first portion, referred to as the main portion, in which the body is covered by the coating layer, a second portion, referred to as the intermediate portion, in which the body is covered with residue of the coating layer, and a third portion, referred to as the stripped portion, in which the body is bare. The intermediate portion is arranged between the main portion and the stripped portion.