Windings Insulation Shape/Form/Construction TRIZ Cases

A guide beside the stator core constrains opening jigs during coil insertion, preventing insulating member breakage and jamming.

Winding insulation together with multi-strand stator conductors reduces bend damage, coil distortion, and slot integration issues.

Folded tang terminals on a non-conductive stator mount simplify magnet wire connection, reducing motor length and brush wear in power tools.

Interturn insulation added during winding helps multi-strand stator coils keep a smooth shape while reducing insulation damage and bulk.

Embedded fluid channels in the insulation between stator coil units improve cooling, cut parts, and prevent short circuits.

A bendable regulating member threaded through insulator openings secures stator coil bridging wires and helps prevent fall-off and short-circuiting.

A porous inner layer and resin outer layer raise partial discharge inception voltage while resisting insulation film cracks during bending.

Housing ribs engage stator insulator protrusions to stop slip and simplify stator assembly, improving motor reliability.

Side closure ring segments form resin-filled vessels around stator contact points to block leakage currents with less casting material and process complexity.

Groove-shaped terminal sections equalize phase resistance in layered motor bus bars, reducing torque harmonics and simplifying assembly.

Connecting rings larger than the rotor enable insertion from either axial side while limiting stator growth and wire interference.

Concentrated multi-layer flat-wire windings improve stator slot fill while reducing wire intersections and winding complexity.

Curved funnel-shaped winding slots reduce wire twisting and gaps, raising slot fill factor and circular wire motor performance.

Mechanical locking rings secure preformed stator coils against axial, radial, and tangential movement where potting is unsuitable.

Selective coating on stator tooth parts leaves yokes uncoated, preventing rolling size deviations, scrap, and added manufacturing cost.

A coolant passage and insulating member keep the neutral point terminal thermally separated from the coil end to prevent overheating and efficiency loss.

Distinct thermoplastics with separated melting points let wound rotor motor plastics and metals be recovered in a simpler recycling process.

A short stator core uses added magnetic material and a denser outer insulator to preserve flux efficiency while reducing motor noise.

Contour-matched enveloping elements form a uniform casting layer on stator end windings, reducing mold wear, cleaning, and insulation cost.

Overlapping stator insulator flanges increase creepage distance at tooth tips, reducing partial discharge and eliminating connecting pins.

Separate stator teeth and a central connecting module enable compact high-torque bicycle motors with lower noise and faster assembly.

Collar-secured filling fixes rotor windings in axial grooves, cutting rotor weight, parts, and assembly complexity while improving cooling.

Stacked bus bars, spacers, and pins replace spot-welded pin connectors to cut stator NVH while improving alignment, insulation, and weld quality.

A thermistor placed in the stator neutral bar gives real-time motor temperature feedback, allowing controller power limiting to prevent overheating.

Resin bobbins and positioning protrusions align fragile pressed powder stator teeth to improve assembly and maintain magnetic flux flow.

A polymer layer seals winding-end gaps during casting, improving stator heat dissipation while avoiding complex tooling and hotspot formation.

Predetermined spacing and stripping lengths in stator hairpin joints limit coating damage during welding and reduce insulation breakdown risk.

Pre-connecting segment conductor ends before core insertion removes welding tool space, keeping the armature compact and easier to assemble.

Layered coil insulation with corona suppression and voltage grading reduces breakdown risk, saves slot space, and supports higher machine ratings.

Thermal crimping joins insulated multistrand stator windings to conductive studs, cutting AC losses while improving connection reliability.

Pre-formed rectangular conductors are nested into narrow ESP stator slots to cut winding time, reduce damage, and raise copper fill ratio.

Annular coolant channels between paired coil discs improve cooling while variable winding thickness preserves compactness and electromagnetic efficiency.

Selective insulation between overlapping hairpin protrusions suppresses partial discharge under voltage surges while reducing insulator size and cost.

Friction-fit stator wedges and slot liners improve conductor retention, ease insertion, and support more accurate PDIV measurement.

Overlapping passive winding regions and thicker active sections raise copper fill while preserving electromagnetic efficiency in compact multiphase coils.

Radially offset conductor segments and low-heat overlay welding improve stator manufacturability while protecting insulation at higher voltage and current.

Tip-piece stator teeth catch wound coils and an outer cylindrical support improves alignment, strength, and motor reliability.

Soft-magnetic members embedded in the armature insulator improve magnetic flux use, raising slotless motor torque without increasing size.

Q-axis current correction offsets magnet temperature drift in slot-less motors, keeping torque command response stable despite flux changes.

Twisted lamination support points secure stator conductors without special lamellas, reducing wire damage, insulation complexity, and oil-cooling pressure loss.

Insulator guides and protrusions keep stator coils inside the molding portion during over-molding, reducing short-circuit risk and extra forming steps.

Laminated core sheets create resin-filled window portions that reinforce the armature while preserving a constant air gap and motor torque.

Thermoplastic posts and receptacles secure motor bus bars to stator insulators, improving connection stability under heat and vibration.

A toothed star element and segmented yoke ring let distributed windings be inserted from outside without bar deformation, improving torque yield.

Nested stator windings and coolant-flow spacers improve heat transfer and voltage induction in compact axial flux machines.

A recessed stator insulation layout preserves active air-gap surface area while maintaining electrical clearance and boosting axial flux machine power density.

Deformable stator cap hooks pre-center round winding wires during joining, enabling reliable automated phase contacting without slippage.

By mixing large and small divisional coils, this stator winding cuts coil count, eases slot insertion, and reduces copper loss.

A two-part stator insulation structure uses a segmented collar and closing element to ease insertion while fully covering the pole shoe.

Cold-plate and retention isolation protect the permanent magnet from winding heat and stress, enabling higher power density with lower degradation.