Coil unit and method of manufacturing coil unit
AssigneeAster Co., Ltd.
InventorTakenobu Hongo
Life of this patent
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Abstract
A coil unit and a manufacturing method of the same are provided which are configured to simplify the configuration of a connection portion between a coil and a wiring material (busbar), to simplify the number of components and a connection step, to prevent an increase in resistance at the connection portion, and to achieve a good connection state. A busbars-welded coil includes a coil made of a wound first metal material, and busbars made of a second metal material connected to end portions of the coil. A welded portion between the end portion of the coil and the busbar is configured by pressure welding with end surfaces butted against each other.
Claims15
A coil unit comprising:
- a coil made of a wound first metal material;
- and
- a busbar made of a second metal material connected to an end portion of a winding of the coil on a winding start side and/or a winding end side, wherein
- a welded portion between the end portion and the busbar is configured by pressure welding with end surfaces butted against each other;
- the coil is bent in one direction;
- the coil constitutes a helical structure body by welding a plurality of strip-shaped flat conductors;
- the coil has a coil straight portion that is continuous from the end surface of the coil and that extends in a direction crossing the end surface and of a long side of the winding;
- the busbar is constituted by a flat conductor;
- the busbar has a busbar straight portion that is continuous from the end surface of the busbar;
- and
- the end surfaces of the busbar and coil are butted against each other along an extending direction of a straight line between the busbar straight portion and the coil straight portion that extends in the direction of the long side of the winding.
A method of manufacturing a coil unit for connecting a busbar made of a second metal member to an end portion of a winding of a coil, which is made of a wound first metal member, on a winding start side and/or a winding end side, comprising:
- the coil constitutes a helical structure body by strip-shaped flat conductors;
- the coil is bent in one direction,
- the coil has a coil straight portion that is continuous from an end surface of the coil and that extends in a direction crossing the end surface and of a long side of the winding;
- the busbar is constituted by a flat conductor;
- the busbar has a busbar straight portion that is continuous from an end surface of the busbar, that extends in a direction crossing the end surface, and has a straight region that is continuous from a first end portion of the busbar and along a press direction in a press step of pressure welding, a length of the straight region being longer than a press length, the press length being a length to be shortened in the press step;
- and
- the end surfaces of the busbar and coil are butted against each other along an extending direction of a straight line between the busbar straight portion and the coil straight portion that extends in the direction of the long side of the winding.
Dependencies are inferred from the claim text.