Joined assembly and production method thereof

Patent metadata

Field	Value
Publication number	US-2024146139-A1
Application number	US-202418405533-A
Country	US
Kind code	A1
Filing date	Jan 5, 2024
Priority date	Jul 9, 2021
Publication date	May 2, 2024
Grant date	—

Abstract

A joined assembly comprises a wire bundle and a metallic member joined to the wire bundle. The wire bundle includes a bundle of a plurality of conductive wires which are isolated from each other using inter-wire insulating layers and adhered to each other, the inter-wire insulating layers being made from insulating resin. The wire bundle includes a head portion and a head extension. The head portion is arranged on a first side of the wire bundle in a lengthwise direction (Da) thereof. The head extension extends from the head portion to a second side of the wire bundle away from the first side in the lengthwise direction. The metallic member includes a metallic member connecting portion arranged in contact with the head extension. The conductive wires are kept adhered to each other through the inter-wire insulating layers in the head extension and fusion-joined in the head portion to a portion of the metallic member connecting portion. The head portion of the wire bundle has the inter-wire insulating layers removed therefrom.

First claim

1 . A joined assembly comprising:
a wire bundle; and a metallic member joined to the wire bundle, wherein the wire bundle includes a bundle of a plurality of conductive wires which are isolated from each other using inter-wire insulating layers and adhered to each other, the inter-wire insulating layers being made from insulating resin, the wire bundle includes a head portion and a head extension, the head portion being arranged on a first side of the wire bundle in a lengthwise direction (Da) thereof, the head extension extending from the head portion to a second side of the wire bundle away from the first side in the lengthwise direction, the metallic member includes a metallic member connecting portion arranged in contact with the head extension, the conductive wires are kept adhered to each other through the inter-wire insulating layers in the head extension and fusion-joined in the head portion to a portion of the metallic member connecting portion, the head portion of the wire bundle has the inter-wire insulating layers removed therefrom.

2 . The joined assembly as set forth in claim 1 , wherein the insulating resin is defined as a first insulating resin,
the wire bundle includes an outer insulating layer made of a second insulating resin, the outer insulating layer is configured to cover the conductive wires within a portion of the wire bundle which is located on the second side away from the head extension in the lengthwise direction.

3 . The joined assembly as set forth in claim 2 , wherein the outer insulating layer is stripped from the head extension.

4 . The joined assembly as set forth in claim 1 , wherein the inter-wire insulating layers have an average thickness of 3 to 30 μm.

5 . The joined assembly as set forth in claim 1 , wherein the wire bundle has the conductive wires twisted in a form of a twisted-wire conductor,
the conductive wires are kept twisted within the head extension.

6 . A production method for a joined assembly including a wire bundle and a metallic member, comprising:
using a bundle of a plurality of conductive wires as the wire bundle, the conductive wires being isolated from each other through inter-wire insulating layers made from insulating resin; holding a head portion of the wire bundle in contact with a metallic member connecting portion of the metallic member, the head portion being arranged on a first side of the wire bundle in a lengthwise direction (Da) of the wire bundle, the head extension extending from the head portion to a second side of the wire bundle away from the first side in the lengthwise direction, the conductive wires being kept adhered to each other through the inter-wire insulating layer within the head extension, and making an end-to-end joint which is created by fusion-joining the conductive wires within the head portion of the wire bundle to a portion of the metallic member connecting portion after the head extension is retained to the metallic member connecting portion, wherein the end-to-end joint is created by emitting an energy beam to fuse and weld the head portion of the wire bundle to the portion of the metallic member connecting portion and also to remove the inter-wire insulating layers from the head portion.

7 . The production method as set forth in claim 6 , wherein the metallic member is made from one of copper and copper alloy,
the conductive wires are made from one of copper and copper alloy, the end-to-end joint is produced by using a laser beam whose wavelength is 400 nm to 600 nm in a form of the energy beam.

8 . The production method as set forth in claim 6 , wherein the inter-wire insulating layers have an average thickness of 3 to 30 μm.

9 . The production method as set forth in claim 6 , wherein emission of the energy beam is performed multiple times.

10 . The production method as set forth in claim 6 , wherein the end-to-end joint is created by steps of emitting the energy beam whose energy density (Ed) is set to a first level (E1) to remove the inter-wire insulating layers from the head portion and then emitting the energy beam whose energy density is changed to a second level (E2) which is higher than the first level to fusion-join the head portion of the wire bundle to the portion of the metallic member connecting portion.

11 . The production method as set forth in claim 6 , wherein the wire bundle has the conductive wires twisted in a form of a twisted-wire conductor, and
holding the head portion of the wire bundle in contact with the metallic member connecting portion of the metallic member is achieved by retaining the head extension in contact with the metallic member connecting portion with the conductive wires being kept twisted within the head extension.

Assignees

• Denso Corp

Inventors

• Koda Kazuki
• Shirai Hideaki
• SHIMOSAKAMOTO Tsuguya

Classifications

• H02K15/35 Primary

  Form-wound windings · CPC title

• H02K3/47 Primary

  Air-gap windings, i.e. iron-free windings · CPC title

• H02K15/061

  Air-gap windings · CPC title

• H01F5/04

  Arrangements of electric connections to coils, e.g. leads · CPC title

• H01R43/02

  for soldered or welded connections · CPC title