Rotary-electric-machine stator coil, rotary-electric-machine stator having the same, and rotary electric machine having the same

Patent metadata

Field	Value
Publication number	US-11088583-B2
Application number	US-201515538063-A
Country	US
Kind code	B2
Filing date	Nov 18, 2015
Priority date	Dec 26, 2014
Publication date	Aug 10, 2021
Grant date	Aug 10, 2021

Abstract

Provided are a rotary-electric-machine stator coil, a rotary-electric-machine stator having the same, and a rotary electric machine having the same, capable of improving a bonding strength and insulation reliability of a conductor bonding portion. A rotary-electric-machine stator coil includes: a conductor 110 having a bonding portion 104 bonded to other conductors; and a bonding member 401 having a melting point lower than a melting point of the conductor, wherein a tip of the bonding portion has an alloy layer 402 formed of an alloy of the conductor and the bonding member, and a root of the bonding portion is electrically connected by the bonding member.

First claim

The invention claimed is:

1. A rotary-electric-machine stator coil comprising:
a conductor having a bonding portion bonded to other bonding portions of neighboring conductors; and
a bonding member, wherein
a tip of the bonding portion has an alloy layer formed of a melted part of the bonding portion of the conductor and the bonding member,
a root of the bonding portion is electrically bonded by brazing the bonding member with at least one root of the neighboring bonding portion of the neighboring conductor,
the conductor is a coil conductor,
a melting point of the alloy layer and a melting point of the bonding member are lower than a melting point of the coil conductor, and
the bonding portion is formed in a T-shape.

2. The rotary-electric-machine stator coil according to claim 1 , wherein the alloy layer has an approximately T-shape in a cross-sectional view along an axial direction of the conductors.

3. The rotary-electric-machine stator coil according to claim 1 , wherein the alloy layer is formed by collectively bonding tips of three or more bonding portions and has an approximately comb tooth shape in a cross-sectional view of the conductors.

4. The rotary-electric-machine stator coil according to claim 1 , wherein the conductor is formed of oxygen-free copper or oxygen-containing copper.

5. The rotary-electric-machine stator coil according to claim 1 , wherein an angled portion or a spherical portion is provided in the tip of the bonding portion.

6. The rotary-electric-machine stator coil according to claim 1 , wherein a cross-sectional shape of the conductor is rectangular or circular.

7. The rotary-electric-machine stator coil according to claim 1 , further comprising another conductor for connection to an external power source, wherein
a tip of the bonding portion of the conductor and a tip of the another conductor for connection to the external power source have an alloy layer formed by melting a part of the bonding portion of the conductor,
a part of the another conductor and the bonding member supplied to the tips of the bonding portion and the another conductor during bonding so as to make a build-up welding configuration, and
a root of the bonding portion of the conductor is electrically bonded by brazing of the bonding member with the another conductor.

8. A rotary-electric-machine stator comprising:
the rotary-electric-machine stator coil according to claim 1 ; and
a stator core,
wherein the conductor is continuously wound around the entire circumference of the stator core to form the stator coil.

9. A rotary electric machine comprising:
the rotary-electric-machine stator according to claim 8 ; and
a rotor.

Assignees

• Hitachi Automotive Systems Ltd

Inventors

• Fukuda Tomohiro
• Nakayama Kenichi
• Ojima Kazuo
• Onose Shin
• Shimizu Hisaya
• Yamazaki Shinji

Classifications

• H02K15/35

  Form-wound windings · CPC title

• H02K15/33

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

• H02K3/12 Primary

  arranged in slots · CPC title

• H02K3/28 Primary

  Layout of windings or of connections between windings (windings for pole-changing H02K17/06, H02K17/14, H02K19/12, H02K19/32) · CPC title

• H01R4/021

  between two or more cables or wires · CPC title