Bobbinless Coil for Rotating Electrical Machine
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Solution Overview
Problem
In rotating electrical machines, the use of a bobbin reduces the space available for the conductor, limits heat dissipation, and results in uneven resin coverage, which can lead to insulation breakdown and reduced output.
Innovation Solution
A coil configuration without a bobbin, where the conductor is wound and pressure-moulded to match the slot shape, and covered with a resin that provides insulation and high thermal conductivity, allowing for increased conductor diameter and improved heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a bobbin is used to wind the conductor, then the conductor can be securely held and insulated, but the space available for the conductor inside the slot decreases
Solution Approach 1:
The invention extracts and removes the bobbin from the coil structure. By eliminating the bobbin entirely, the conductor is wound directly and inserted into the slot without the intermediate support structure, thereby maximizing the conductor space within the slot while maintaining insulation through alternative means (resin coating and slot insulation)
Solution Approach 2:
The invention merges the functions of the bobbin (support and insulation) into integrated solutions: the resin coating provides both insulation and structural support, while the slot design itself provides mechanical support for the conductor bundle, eliminating the need for a separate bobbin component
2Temperature
If a bobbin is used to support the conductor, then the conductor is held in place, but heat dissipation efficiency decreases
Solution Approach 1:
The bobbin is extracted and removed from the structure. Without the bobbin's insulating barrier between the conductor and the external environment, heat can dissipate more efficiently from the conductor directly to the surrounding air and to the slot structure, improving thermal management
Solution Approach 2:
The invention uses resin materials with high thermal conductivity properties to coat the conductor. This resin material provides both electrical insulation and enhanced heat dissipation capabilities, creating a composite structure that addresses both insulation and thermal management requirements simultaneously
3Reliability
If resin is applied to cover the conductor, then insulation is provided, but the covering layer thickness becomes uneven leading to insulation breakage
Solution Approach 1:
The conductor is pre-wound into a compact, uniform coil structure before insertion into the slot. This preliminary structuring ensures that when resin is applied, it distributes more evenly across the surface, reducing thickness variation and preventing insulation breakage
Solution Approach 2:
The invention changes the physical state and properties of the resin material, using materials with specific viscosity and curing characteristics that enable more uniform coating application. The resin parameters are optimized to ensure even distribution and consistent thickness across the conductor surface
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
This configuration increases the output of the rotating electrical machine by optimizing conductor space and heat management, while ensuring reliable insulation and reduced risk of insulation breakdown.
Implementation Method 1
covered with a resin that provides insulation and high thermal conductivity
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
[Object] To increase an output of a rotating electrical machine. [Solving means] A coil 30 configured to be inserted into slots 21 of a stator core 22 of a rotating electrical machine 1, comprises a wound body 34 that is configured by winding a conductor 31 covered by an insulating film 33 made of a first resin along a revolving direction and is pressure-moulded so that its outer shape matches a shape of the corresponding slot 21, and a resin covering 35 that is made of a second resin 53 that differs from the first resin and covers a surface of the wound body 34.