Conductor Unit Air Removing Portion Insulation Faults
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Solution Overview
Problem
In rotating electrical machines, gaps between resin and conductors can form during cooling, leading to air bubbles and insulation faults when powder coating is applied, reducing insulativity and requiring repairs.
Innovation Solution
Incorporating an air removing portion in the resin portion, such as a circular or slit-shaped hole, to discharge expanding air and using a sealant introduction portion to fill gaps between the resin and conductor, ensuring effective insulation and preventing faults.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If powder coating is implemented on the resin portion to form insulation, then insulativity is improved, but air bubbles and air gaps are generated reducing insulation quality
Solution Approach 1:
The air removing portion is formed in the resin portion before powder coating is applied. This preliminary structural feature allows air to be discharged during the subsequent powder coating process, preventing air bubble formation and maintaining insulation quality.
Solution Approach 2:
The air removing portion acts as an intermediary channel between the gap space and the external environment. It mediates the discharge of expanding air during powder coating, preventing air from forming harmful bubbles within the insulation layer.
2Productivity
If integral forming is used to combine resin and conductor, then manufacturing efficiency is improved, but gaps are generated between resin inner surface and conductor
Solution Approach 1:
The air removing portion creates a controlled porous or channelled structure within the otherwise solid resin portion. This allows the resin to maintain its encapsulating function while providing a designated path for air evacuation, converting the harmful gap into a functional feature.
3Reliability
If the gap between resin and conductor is sealed, then insulation is improved, but air expansion during powder coating causes defects
Solution Approach 1:
Instead of sealing the gap and trapping air, the invention extracts the air from the gap space by providing an escape route through the air removing portion. This removes the harmful factor (trapped air) while maintaining the beneficial encapsulation of the resin.
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 air removing and sealant introduction features prevent air bubbles and gaps, enhancing insulation reliability and manufacturability, thereby reducing the likelihood of insulation-related faults and repair needs.
Implementation Method 1
The gap is generated by contraction of the resin part during cooling of the integral forming.
Implementation Method 2
air that exists in the gap is heated to expand sometimes, and consequently, an air bubble, an air gap (a trace of air injection), or the like, is generated on an insulation portion formed by powder coating
Data Source
AI summary
The present invention provides a conductor unit, which hardly generates an insulation-related fault, for a rotating electrical machine, and a rotating electrical machine. A supply line unit (30) of the rotating electrical machine comprises a conductor (35) and a resin part (32) that encapsulates at least a part of the conductor (35), where the resin portion has an air removing portion (51) leading to the conductor (35) in a powder coating coverage area (52), in which powder coating is further implemented on the resin part (32).