Method for bonding electrical conductors

Patent metadata

Field	Value
Publication number	US-10892670-B2
Application number	US-201815920712-A
Country	US
Kind code	B2
Filing date	Mar 14, 2018
Priority date	Mar 15, 2017
Publication date	Jan 12, 2021
Grant date	Jan 12, 2021

Abstract

A method for bonding electrical conductors is provided that is capable of suppressing a power source capacity when assembling a stator having a specific structure. First, coil pieces 9 are arranged in contact with bonding portions of a slot coil 5 inserted in a slot of a stator iron core 2 via a metal paste. Subsequently, an electrical current is applied using a pair of electrodes 11A and 11B in the axial direction (upward and downward in the figures) of the slot coil 5 while contact portions 15 between the slot coil 5 and the coil pieces 9 are pressed in an axial direction of the slot coil 5. As a result, electricity flows in the axial direction the coil piece 9 (a direction of an arrow X in the figures).

First claim

What is claimed is:

1. A method for bonding electrical conductors that bonds conductor members and connection conductor members in a stator where a plurality of slots are formed in an annular stator iron core along a circumferential direction thereof, linear conductor members are inserted into the slots respectively such that bonding portions of each of the conductor members on both sides in an axial direction thereof protrude from the slot, and the conductor members inserted in different slots of the plurality of slots are sequentially bonded with the connection conductor members so that the conductor members and the connection conductor members are electrically connected to each other to form a coil, the method comprising:
an arrangement process of arranging the connection conductor members in contact with the bonding portions of the conductor members via a metal paste; and
a current application process of applying an electrical current in the axial direction of the conductor members with use of a pair of electrodes while pressing contact portions between the conductor members and the connection conductor members in the axial direction of the conductor members,
wherein, in the arrangement process, the connection conductor members are placed in contact with the bonding portions on both sides in the axial direction of the conductor members via the metal paste, respectively, and
wherein, in the current application process, the electrical current is applied between the pair of electrodes in the axial direction of the conductor members while the contact portions between the conductor members and the connection conductor members are pressed by the electrodes in the axial direction of the conductor members.

2. A method for bonding electrical conductors that bonds conductor members and connection conductor members in a stator where a plurality of slots are formed in an annular stator iron core along a circumferential direction thereof, linear conductor members are inserted into the slots respectively such that bonding portions of each of the conductor members on both sides in an axial direction thereof protrude from the slot, and the conductor members inserted in different slots of the plurality of slots are sequentially bonded with the connection conductor members so that the conductor members and the connection conductor members are electrically connected to each other to form a coil, the method comprising:
an arrangement process of arranging the connection conductor members in contact with the bonding portions of the conductor members via a metal paste; and
a current application process of applying an electrical current in the axial direction of the conductor members with use of a pair of electrodes while pressing contact portions between the conductor members and the connection conductor members in the axial direction of the conductor members,
wherein, in the arrangement process:
a first connection conductor member is arranged in contact with an arbitrary first conductor member of the conductor members via the metal paste at a bonding portion of the first conductor member on one side in an axial direction thereof while arranging a second connection conductor member in contact with the first conductor member via the metal paste at a bonding portion of the first conductor member on an other side in the axial direction thereof;
a third connection conductor member is arranged in contact with an arbitrary second conductor member, which is different from the first conductor member, of the conductor members via the metal paste at a bonding portion of the second conductor member on one side in an axial direction thereof while arranging a fourth connection conductor member in contact with the second conductor member via the metal paste at a bonding portion of the second conductor member on an other side in the axial direction thereof; and
the bonding portion of the second connection conductor member and the bonding portion of the fourth connection conductor member is electrically connected to each other via a relay electrode, and
wherein, in the current application process,
the electrical current is applied between the pair of electrodes while contact portions between the first conductor member and the first connection conductor member and the second connection conductor member are pressed by one of the pair of electrodes and the relay electrode in the axial direction of the first conductor member, and
contact portions between the second conductor member and the third connection conductor member and the fourth connection conductor member are pressed by the other of the pair of electrodes and the relay electrode in the axial direction of the second conductor member.

3. A method for bonding electrical conductors that bonds conductor members and connection conductor members in a stator where a plurality of slots are formed in an annular stator iron core along a circumferential direction thereof, linear conductor members are inserted into the slots respectively such that bonding portions of each of the conductor members on both sides in an axial direction thereof protrude from the slot, and the conductor members inserted in different slots of the plurality of slots are sequentially bonded with the connection conductor members so that the conductor members and the connection conductor members are electrically connected to each other to form a coil, the method comprising:
an arrangement process of arranging the connection conductor members in contact with the bonding portions of the conductor members via a metal paste; and
a current application process of applying an electrical current in the axial direction of the conductor members with use of a pair of electrodes while pressing contact portions between the conductor members and the connection conductor members in the axial direction of the conductor members,
wherein a cross-sectional area of a portion of the conductor members facing the contact portion is smaller than a cross-sectional area of a portion of the conductor members not facing the contact portion.

4. A method for bonding electrical conductors that bonds conductor members and connection conductor members in a stator where a plurality of slots are formed in an annular stator iron core along a circumferential direction thereof, linear conductor members are inserted into the slots respectively such that bonding portions of each of the conductor members on both sides in an axial direction thereof protrude from the slot, and the conductor members inserted in different slots of the plurality of slots are sequentially bonded with the connection conductor members so that the conductor members and the connection conductor members are electrically connected to each other to form a coil, the method comprising:
an arrangement process of arranging the connection conductor members in contact with the bonding portions of the conductor members via a metal paste; and
a current application process of applying an electrical current in the axial direction of the conductor members with use of a pair of electrodes while pressing contact portions between the conductor members and the connection conductor members in the axial direction of the conductor members,
wherein a cross-sectional area of a portion of the connection conductor members facing the contact portion is smaller than a cross-sectional area of a portion of the connection conductor members not facing the contact portion.

5. A method for bonding electrical conductors that bonds conductor members and connection conductor members in a stator where a plurality of slots are formed in an annular stator iron core along a circumferential direction thereof, linear conductor members are inserted into the slots respectively such that bonding portions of each of the conductor members on both

Assignees

• Honda Motor Co Ltd

Inventors

• Yoshida Kotaro
• Iura Satonori
• Eguchi Toru
• Matsuo Kazuhide
• Ueda Takeshi

Classifications

• H02K15/021

  Magnetic cores · CPC title

• H02K15/33 Primary

  Connecting winding sections; Forming leads; Connecting leads to terminals · CPC title

• H02K15/085 Primary

  by laying conductors into slotted stators · CPC title

• B23K1/0004

  Resistance soldering · CPC title

• B23K11/18

  of non-ferrous metals (B23K11/20 takes precedence) · CPC title