Rotating electric machine and method of manufacturing same

Patent metadata

Field	Value
Publication number	US-10075039-B2
Application number	US-201615219752-A
Country	US
Kind code	B2
Filing date	Jul 26, 2016
Priority date	Jul 28, 2015
Publication date	Sep 11, 2018
Grant date	Sep 11, 2018

Abstract

A rotating electric machine includes a weld formed by welding end portions of a pair of electric conductors for forming a coil and a weld-insulating member that covers, at least, a surface of the weld. The weld has an uneven portion formed on at least part of the surface thereof. The uneven portion is constituted of a plurality of annular recesses and a plurality of annular protrusions. The annular recesses are formed alternately and continuously with the annular protrusions.

First claim

What is claimed is:

1. A rotating electric machine comprising:
a weld formed by welding end portions of a pair of electric conductors for forming a coil; and
a weld-insulating member that covers, at least, a surface of the weld,
wherein
the weld has an uneven portion formed on at least part of the surface thereof, and
the uneven portion is constituted of a plurality of annular recesses and a plurality of annular protrusions, the annular recesses being formed alternately and continuously with the annular protrusions.

2. The rotating electric machine as set forth in claim 1 , wherein the weld is formed so that when viewed from an opposite side of the weld to the pair of electric conductors, a region surrounded by an outline of the weld is within a region surrounded by an outline of the pair of electric conductors.

3. The rotating electric machine as set forth in claim 1 , further comprising a pair of conductor-insulating members that respectively cover entire outer peripheries of the pair of electric conductors except for the end portions of the pair of electric conductors,
wherein
each of the pair of conductor-insulating members has an increased-diameter portion formed adjacent to the end portion of the respective one of the pair of electric conductors so as to be increased in diameter in a direction toward the end portion of the respective electric conductor, and
the weld-insulating member covers the increased-diameter portions of the pair of conductor-insulating members as well as the surface of the weld.

4. The rotating electric machine as set forth in claim 1 , wherein the uneven portion is formed on the surface of the weld except for a predetermined area of the surface, the predetermined area being adjacent to the pair of electric conductors.

5. A method of manufacturing the rotating electric machine as set forth in claim 1 , the method comprising:
welding the end portions of the pair of electric conductors to form the weld; and
forming the uneven portion by pressing a die, which has protrusions and recesses formed therein, against the surface of the weld.

6. A method of manufacturing the rotating electric machine as set forth in claim 1 , the method comprising:
welding the end portions of the pair of electric conductors to form the weld; and
forming the uneven portion by cutting the surface of the weld with a cutting tool.

7. A method of manufacturing the rotating electric machine as set forth in claim 1 , the method comprising:
welding the end portions of the pair of electric conductors to form the weld; and
forming the uneven portion, during the welding of the end portions of the pair of electric conductors, by vibration of molten parts of the end portions of the pair of electric conductors, the vibration being caused by at least one of a shield gas flow and a magnetic field created during the welding.

8. The method as set forth in claim 7 , wherein each of the pair of electric conductors is constituted of a plurality of electric conductor wires.

9. The method as set forth in claim 8 , wherein each of the electric conductor wires has a circular cross-sectional shape.

Assignees

• Denso Corp

Inventors

• Ishizuka Atsuo
• Kaneiwa Hiroshi
• Kondou Keiji
• Asai Hiromitsu

Classifications

• H02K3/38

  around winding heads, equalising connectors, or connections thereto · CPC title

• H02K3/12 Primary

  arranged in slots · CPC title

• H02K3/32

  Windings characterised by the shape, form or construction of the insulation · CPC title

• H02K3/04

  Windings characterised by the conductor shape, form or construction, e.g. with bar conductors · CPC title

• H02K15/0081

  Electricity · mapped topic