Contacting Method for Lacquer-Insulated Conductors

Simple SummaryContent extracted from patent full text and abstract with AI.

This patent describes a method for connecting lacquer-insulated conductors (wires and strands) in coil windings for electric motors or transformers. The process proposes first removing the insulation from the wire ends using ultrasonic compacting, which also partially joins the wires, and then using laser welding to create a strong, electrically conductive joint between the wires. This allows for a higher density of connection points within a limited space, and eliminates the need for extra components like sleeves or additional soldering materials.

Use CasesContent extracted from patent full text and abstract with AI.

• Manufacture of stator or rotor windings for electric motors, especially traction motors for electric vehicles
• Production of compact transformers with high winding densities
• Creating reliable electrical joints in windings for industrial generators and alternators
• Integrating electronic components (such as sensors or protection devices) directly into motor or transformer windings
• Assembly of miniature or high-power-density electrical machines where space is limited
• Automated, high-throughput production lines for winding assembly in the electric motor industry

BenefitsContent extracted from patent full text and abstract with AI.

• Enables a higher density of electrical connections, maximizing copper fill and improving motor/transformer efficiency
• Removes the need for extra connectors, sleeves, or solder, reducing material costs and production complexity
• Improves process reliability and repeatability, making it suitable for large-scale automated manufacturing
• Results in electrically superior and mechanically strong connections thanks to precise welding and compaction steps
• Reduces space requirements for connections, contributing to more compact winding designs
• Allows for integration of electronic components directly at winding nodes, enhancing device functionality and reducing assembly steps

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

In order to allow for as high a density of connecting nodes as possible in as small an amount of space as possible, the invention proposes that ultrasonic compacting of the conductor end pieces to be connected is first performed in order to remove insulation enamel and, in a subsequent step, a cohesive connection is made by means of laser welding between the conductor end pieces to be connected.