# US 12,003,149 B2 · Coil unit and method of manufacturing coil unit > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,003,149 B2 - Document ID: US12003149B2 - Status: Granted - Kind: B2 - Application number: 17/427,299 - Filed: 2020-01-31 - Published: 2022-04-28 - Granted: 2024-06-04 - Earliest claimed: 2019-02-19 - Assignees: Aster Co., Ltd. - Applicants: Aster Co., Ltd. - Inventors: Takenobu Hongo - Web page: https://patentgrep.com/patent/US12003149B2 ## CPC - H02K 15/35: Form-wound windings - H01F 5/00: Coils (superconducting coils H01F6/06; fixed inductances of the signal type H01F17/00) - H02K 3/02: Windings characterised by the conductor material - H02K 3/04: Windings characterised by the conductor shape, form or construction, e.g. with bar conductors - H02K 3/18: Windings for salient poles - H02K 3/522: {for generally annular cores with salient poles} - H02K 15/0414: the windings consisting of separate elements, e.g. bars, segments or half coils - H01F 27/2847: {Sheets; Strips (H01F27/2866 takes precedence)} - H02K 2203/09: Machines characterised by wiring elements other than wires, e.g. bus rings, for connecting the winding terminations - H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53}) - H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES ## 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. ## Claims ### Claim 1 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. ### Claim 2 (depends on 1) The coil unit according to claim 1, wherein the first metal material and the second metal material are the same type metal materials. ### Claim 3 (depends on 1) The coil unit according to claim 1, wherein the first metal material and the second metal material are different metal materials. ### Claim 4 (depends on 1) The coil unit according to claim 1, wherein welded portions of the plurality of strip-shaped flat conductors are configured by pressure welding end surfaces, which have been butted against each other, of the plurality of strip-shaped flat conductors in a helical traveling direction. ### Claim 5 (depends on 1) The coil unit according to claim 1, wherein the coil is an edgewise coil in which corner portions of winding are configured at a substantially right angle. ### Claim 6 (depends on 1) The coil unit according to claim 1, wherein the coil is covered with a resin. ### Claim 7 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. ### Claim 8 (depends on 7) The method of manufacturing a coil unit according to claim 7, wherein the first metal material and the second metal material are the same type metal materials. ### Claim 9 (depends on 7) The method of manufacturing a coil unit according to claim 7, wherein the first metal material and the second metal material are different metal materials. ### Claim 10 (depends on 7) The method of manufacturing a coil unit according to claim 7, comprising a step of preparing the strip-shaped flat conductors to be a helical structure body when being joined, and butting end faces of the strip-shaped flat conductors in a helical travel direction against each other and pressure welding them to form the coil. ### Claim 11 (depends on 7) The method of manufacturing a coil unit according to claim 7, wherein the flat conductor includes a straight portion and a corner portion, and the corner portion is formed by punching at a substantially right angle. ### Claim 12 (depends on 7) The method of manufacturing a coil unit according to claim 7, comprising a step of covering the coil with a resin. ### Claim 13 (depends on 1) The coil unit according to claim 1, wherein the busbar has the busbar straight portion and at least one direction changing portion which is bent so as to change an extending direction of a strip longitudinal direction. ### Claim 14 (depends on 7) The method of manufacturing a coil unit according to claim 7, wherein the busbar has the busbar straight portion and at least one direction changing portion which is bent so as to change an extending direction of a strip longitudinal direction. ### Claim 15 (depends on 7) The method of manufacturing a coil unit according to claim 7, wherein the flat conductor includes a straight portion and a corner portion, and the corner portion is formed by punching at a substantially right angle.