CNT Plug-In Stator Winding Interconnection Without Soldering
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Solution Overview
Problem
Conventional joining methods, such as welding or soldering, are not suitable for connecting carbon nanotube (CNT) conductor elements in electric machine stators due to insufficient temperature resistance and strength requirements.
Innovation Solution
The use of pluggable CNT conductor elements with electrically non-conductive conductor joining devices, featuring depressions and insertion slits, allows for reliable electrical connection via an electrically conductive joining agent, ensuring mechanical and electrical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional joining methods (welding or soldering) are used to connect CNT conductor elements, then strong electrical connection is achieved, but temperature resistance and strength requirements are not fulfilled
Solution Approach 1:
The patent introduces an electrically conductive joining agent as an intermediary substance between the CNT conductor elements and the interconnecting ring. This joining agent provides both mechanical adhesion and electrical conductivity, serving as a mediator that enables reliable connection without requiring high-temperature welding or soldering processes that would damage the CNT materials.
Solution Approach 2:
The patent replaces the conventional thermal-joining system (welding/soldering) with a mechanical-chemical joining system using adhesive bonding. The joining agent creates mechanical interlocking and chemical adhesion between components, eliminating the need for high-temperature thermal processes that are incompatible with CNT conductor elements.
2Reliability
If conventional joining methods are used, then electrical connection is achieved, but mechanical strength requirements are not fulfilled
Solution Approach 1:
The joining agent acts as a mediator that provides both mechanical adhesion strength and electrical conductivity. It creates strong mechanical bonds between the CNT conductor elements and the interconnecting ring through adhesion and interlocking mechanisms, while simultaneously maintaining electrical continuity.
Solution Approach 2:
The patent employs a composite joining solution that combines organic adhesive properties with conductive fillers. This composite material exhibits both mechanical bonding characteristics for strength and electrical properties for conductivity, satisfying both requirements simultaneously.
3Reliability
If pluggable CNT conductor elements with conductor joining devices are used, then connection reliability is improved, but device complexity increases
Solution Approach 1:
The patent divides the connection system into separate functional components: the CNT conductor elements with conductor ends, the interconnecting ring with integrated conductor joining devices, and the joining agent. This segmentation allows each component to be optimized independently and simplifies assembly through modular plug-in connection.
Solution Approach 2:
The conductor joining devices are integrated directly into the interconnecting ring structure, providing self-contained connection functionality. The depression and insertion slit features are built into the ring itself, eliminating the need for separate joining mechanisms and reducing overall system complexity.
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 solution enables the reliable mechanical and electrical interconnection of CNT conductor elements, fulfilling the requirements of an electric machine stator, while simplifying the connection process and ensuring electrical insulation.
Implementation Method 1
two conductor ends of two different conductor elements are electrically connected to said conductor joining device by means of an electrically conductive joining agent
Data Source
AI summary
A stator of an electric machine is already known, comprising stator teeth and grooves formed between the stator teeth, in which electrical conductor elements of an electrical individual coil winding are provided as individual coils, wherein an interconnection is provided on at least one end side of the stator, which has a ring section and multiple, in particular a number corresponding to the number of stator teeth, tooth sections protruding from the ring section in the radial direction. The interconnection ring comprises multiple bus bars for interconnecting the electrical individual coils of the electrical winding. The individual coils are produced from a conventional conductor material, e.g. copper. In the stator according to the invention, an electrical winding made of CNT conductor elements is provided. According to the invention: the conductor elements (4) of the electrical winding are configured as insertable conductor elements (4) of the electrical winding designed as a plug-in winding; the conductor elements (4) are each formed of a combination of carbon nanotubes and/or graphene fibres; and at least one electrically non-conductive conductor joining device (12) is provided on at least one of the tooth sections (10) of the interconnection ring (5), to which two respective conductor ends of two different conductor elements (4) are electrically connected by means of an electrically conductive joining means.