Conductive Adhesive Lamination Pack for Motor Stators
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Solution Overview
Problem
The existing methods for connecting laminations in electric motor or generator stators/rotors with insulating coatings face challenges in conducting resistance tests without increasing eddy current losses, as traditional methods like welding damage the insulation layers.
Innovation Solution
The use of an adhesive containing electrically conductive particles that penetrates the insulating layers to create a conductive connection between laminations, allowing for easy resistance testing without significant eddy current loss, and the application of an electrically conductive connection on the periphery or surface for measurement purposes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional welding methods are used to connect laminations, then electrical conductive connection is achieved, but the insulating layers are damaged and eddy current losses increase
Solution Approach 1:
The patent introduces an adhesive containing electrically conductive particles as an intermediary substance between the laminations. This adhesive layer mediates the electrical connection while preserving the insulating layers, as the conductive particles penetrate through the insulation to create conductive paths without damaging the underlying structure. This resolves the contradiction by providing a connection method that doesn't require destroying the insulating coating.
Solution Approach 2:
The patent changes the electrical conductivity parameter of the adhesive material from non-conductive to conductive by incorporating conductive particles. This parameter change allows the adhesive to simultaneously provide mechanical bonding and electrical connection, eliminating the need for welding that would damage the insulating layers and reduce eddy current losses.
2Loss of energy
If insulating layers are applied to reduce eddy current losses, then energy efficiency improves, but resistance testing becomes difficult
Solution Approach 1:
The electrically conductive adhesive acts as a mediator that enables resistance testing through the insulating layers. The conductive particles within the adhesive create measurable electrical paths between laminations without compromising the insulating function during operation, thus allowing easy resistance testing while maintaining low eddy current losses.
3Strength
If screws or bolts are used to connect laminations, then mechanical strength is achieved, but the insulating layers are penetrated and eddy current losses increase
Solution Approach 1:
The patent replaces the mechanical connection method (screws or bolts) with a chemical/adhesive bonding method containing conductive particles. This substitution eliminates the need to mechanically penetrate the insulating layers, as the adhesive bonds laminations together while the conductive particles within the adhesive provide electrical connection paths without physical penetration, thus maintaining insulation integrity and reducing eddy current losses.
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
Enables accurate resistance testing without damaging the insulation layers and maintains low eddy current losses, as the conductive particles form reliable connections within the laminated core without requiring screws or bolts, and the conductive connections can be easily removed post-measurement.
Implementation Method 1
The lamellas are connected to one another by an adhesive that contains electrically conductive particles. This adhesive is designed in such a way that when the slats are pressed together to create the slat pack, the electrically conductive particles penetrate the insulating layers on the slats.
Implementation Method 2
The lamellas are connected to one another by an adhesive that contains electrically conductive particles
Implementation Method 3
the electrically conductive particles penetrate the insulating layers on the slats
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The laminated core (1) is used to manufacture stators and/or rotors of electric motors and generators. It comprises overlapping and firmly connected laminations (2) with electrically insulating layers (3) between them. Outside the electrically insulating layers (3), the laminations (2) are connected to each other by an electrically conductive connection (4).