An electrical motor stator and compressor
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Solution Overview
Problem
High operating voltages in electric vehicle motors require enhanced insulating properties and pose manufacturing challenges, especially when exposed to conductive coolants and oils, while existing technologies struggle to provide effective insulation and automated manufacturing solutions.
Innovation Solution
An electrical motor stator design featuring a stator assembly with an iron core, wound wires, insulating seats, and conductive contacts, where the contact plate and sleeve seats are integrally injection-molded from insulating material, filled with gel or epoxy resin, and connected using methods like brazing or laser welding, facilitating automated assembly and improved insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional insulating structures are used in high-voltage motors, then manufacturing simplicity is maintained, but insulating properties are insufficient under high voltage and conductive coolant exposure
Solution Approach 1:
The patent employs composite insulating structures combining multiple materials: insulating varnish coatings on windings, insulating sleeves on electrical contacts, and insulating seals in the contact plate. These composite material solutions provide enhanced insulation performance for high-voltage applications while maintaining manufacturing feasibility through standardized material selection and application processes.
2Productivity
If manual assembly methods are used for electrical motor stators, then manufacturing precision can be maintained, but productivity and automation level are low
Solution Approach 1:
The patent divides the electrical motor stator into modular segments: the stator core with windings, the contact plate with integrated insulation, and the insulating sleeves as separate components. This segmentation enables each module to be manufactured and inspected independently with high precision, then assembled through standardized interfaces that facilitate automated assembly while maintaining overall manufacturing precision.
Solution Approach 2:
The patent introduces standardized intermediary components such as insulating sleeves and seal elements that act as mediators between electrical and mechanical systems. These intermediaries provide precise positioning and connection features that enable automated assembly equipment to accurately locate and assemble components, thereby achieving both high productivity and manufacturing precision.
3Reliability
If insulation layers are added to protect against high voltage, then electrical insulation is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the insulation function into existing structural components rather than adding separate insulation layers. The contact plate integrates insulating seals and insulating varnish coatings directly into its structure, and insulating sleeves are combined with electrical contacts as unified components. This merging approach provides necessary electrical insulation while simplifying the manufacturing process by reducing the number of separate assembly steps.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design enhances insulation properties and enables automated manufacturing, ensuring reliable electrical connections and improved safety in high-voltage environments, while simplifying the assembly process and increasing production efficiency.
Implementation Method 1
the gel or epoxy resin is electrically insulating
Implementation Method 2
connected using methods like brazing or laser welding
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present application provides an electrical motor stator and a compressor. The electrical motor stator comprises a stator assembly and contact plate, wherein the stator assembly comprises an iron core; a winding comprising a plurality of wires; a first insulating seat; and a plurality of first electrical contacts fixed to the first insulating seat, wherein the wires extend to and are electrically connected to the first electrical contacts. The contact plate is positioned relative to a stator assembly and comprises a body; a plurality of sleeve seats comprising a first opening, a second opening, and a cavity extending between the first opening and the second opening, wherein the first opening is positioned at a first side of the body and the second opening is positioned at a second side of the body, with the sleeve seats being positioned to correspond to the first electrical contacts and, through the first opening, at least partially accommodating the first electrical contacts within the cavity; a plurality of second electrical contacts comprising a first connecting portion and a second connecting portion, with the first connecting portion disposed within the cavity and in contact with the first electrical contacts, establishing an electrical connection, and the second connecting portion exposed on the second side of the body.