Insulated wire material and method of manufacturing the same, and coil and electrical/electronic equipment

Patent metadata

Field	Value
Publication number	US-11670436-B2
Application number	US-202016816772-A
Country	US
Kind code	B2
Filing date	Mar 12, 2020
Priority date	Mar 30, 2018
Publication date	Jun 6, 2023
Grant date	Jun 6, 2023

Abstract

Provided are an insulated wire material including: a conductor including a single core conductor or a plurality of divided conductors placed in parallel to each other or helically placed; a peripheral insulating layer with which a periphery of the conductor is coated; and a welding member provided at least one end portion of the conductor and joined, via a welded portion welded to the single core conductor or divided conductors, to at least a peripheral surface of the welded portion, a manufacturing method thereof, a coil including the insulated wire material, and electrical/electronic equipment including the coil.

First claim

The invention claimed is:

1. An insulated wire material, including:
a conductor, wherein the conductor is:
a single core conductor having a peripheral insulating layer with which a periphery of the single core conductor is coated; or
a plurality of divided conductors placed in parallel to each other or helically placed having a respective conductor insulating layer sandwiched between the divided conductors, and having a peripheral insulating layer with which a periphery of the plurality of divided conductors is coated; and

a welding member provided at at least one end portion of the conductor and joined, via a welded portion welded to an end surface in the axial direction of the conductor, to at least a peripheral surface of the welded portion, the welding member having one or a plurality of bottomed holes each respectively having an opening on an opposite surface against a surface of the welding member with which the end surface of the conductor faces, the welded portion is at a position contacting and facing the conductor and in the one or the plurality of bottomed holes of the welding member,
wherein the welding member and the conductor are made of a same material, and
wherein the welding member is welded to the conductor by melting, by irradiating with fiber laser beams, and solidifying the welded portion at the position contacting and facing the conductor to form the one or the plurality of bottomed holes.

2. The insulated wire material according to claim 1 , wherein the conductor includes the single core conductor.

3. The insulated wire material according to claim 2 , in which the conductor includes a conductor insulating layer with which a peripheral surface of the single core conductor is coated and the conductor insulating layer is further coated with the peripheral insulating layer.

4. The insulated wire material according to claim 3 , in which the conductor insulating layer is made from organic polymers.

5. The insulated wire material according to claim 3 , in which the conductor insulating layer is an insulating layer having has cells.

6. The insulated wire material according to claim 2 , in which the single core conductor is flat conductor.

7. The insulated wire material according to claim 2 , in which a material of the single core conductor is oxygen-free copper.

8. The insulated wire material according to claim 7 , in which the welded portion contains a tin element.

9. The insulated wire material according to claim 2 , in which a material of the welding member is oxygen-free copper.

10. The insulated wire material according to claim 2 , in which tensile strength of the welded portion is equal to or more than 300 MPa.

11. The insulated wire material according to claim 2 , in which the peripheral insulating layer of the single core conductor is made from polyetheretherketone.

12. The insulated wire material according to claim 2 , in which an area ratio [S c1 :S c2 ] of a cross-sectional area S c1 of the welding member before welding to a cross-sectional area S c2 of the conductor before welding satisfies a range of 1:0.8 to 1.2.

13. A coil including the insulated wire material according to claim 2 .

14. An electrical/electronic equipment, including the coil according to claim 13 .

15. A coil including a plurality of pieces of the insulated wire material according to claim 2 , wherein each of the pieces includes the welding member, wherein the welding members are electrically connected to each other.

16. A method of manufacturing the insulated wire material according to claim 2 , including in a state in which the end surface of the conductor and a portion to be welded of the welding member abut against each other, irradiating the portion to be welded with fiber lasers of the fiber laser beams in a thickness direction of the portion to be welded and welding the end surface and the welding member.

17. The insulated wire material according to claim 1 , wherein the conductor includes the plurality of divided conductors.

18. The insulated wire material according to claim 17 , in which the divided conductors are flat conductors.

19. The insulated wire material according to claim 17 , in which each of the plurality of divided conductors is a ribbon wire.

20. The insulated wire material according to claim 17 , in which each of the plurality of divided conductors is an enameled wire, and the conductor is a flat molded body of strand wires including the enameled wires.

21. The insulated wire material according to claim 17 , in which a material of the divided conductors is oxygen-free copper.

22. The insulated wire material according to claim 21 , in which the welded portion contains a tin element.

23. The insulated wire material according to claim 17 , in which a material of the welding member is oxygen-free copper.

24. The insulated wire material according to claim 17 , in which tensile strength of the welded portion is equal to or more than 300 MPa.

25. The insulated wire material according to claim 17 , in which the peripheral insulating layer of the plurality of divided conductors is made from polyetheretherketone.

26. The insulated wire material according to claim 17 , in which the conductor insulating layer is made from organic polymers.

27. The insulated wire material according to claim 17 , in which the conductor insulating layer has cells.

28. The insulated wire material according to claim 17 , in which an area ratio [S c1 :S c2 ] of a cross-sectional area S c1 of the welding member before welding to a cross-sectional area S c2 of the conductor before welding satisfies a range of 1:0.8 to 1:1.2.

29. A coil including the insulated wire material according to claim 17 .

30. An electrical/electronic equipment, including the coil according to claim 29 .

31. A coil including a plurality of pieces of the insulated wire material according to claim 17 , in which each of the plurality of pieces of the insulated wire material includes the welding member, the welding members of the plurality of pieces of the insulated wire material being electrically connected to each other.

32. A method of manufacturing the insulated wire material according to claim 17 , including in a state in which the end surface of the conductor and a portion to be welded of the welding member abut against each other, irradiating the portion to be welded with fiber lasers of the fibers laser beams in a thickness direction of the portion to be welded and welding the end surface and the welding member.

Assignees

• Furukawa Electric Co Ltd

Inventors

• Tachibana Akira
• Muto Daisuke
• Oshima Hirofumi

Classifications

• H01F27/2828

  Construction of conductive connections, of leads · CPC title

• H02K3/12

  arranged in slots · CPC title

• H01B7/08

  Flat or ribbon cables · CPC title

• H01B1/026 Primary

  Alloys based on copper · CPC title

• H01B3/427

  Polyethers · CPC title