Electrical motor stator and compressor
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Solution Overview
Problem
High operating voltages in electric vehicle motors require enhanced insulating properties and automation in manufacturing to ensure safety and efficiency, particularly in compressors exposed to conductive coolants and oils.
Innovation Solution
An electrical motor stator design featuring an iron core with wound wires, insulating seats, and conductive contacts, integrated with an insulating contact plate and sleeve seats, optionally filled with gel or epoxy resin, allowing for automated assembly and improved electrical connections through methods like brazing or laser welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high voltage operation is implemented to increase power output, then motor power is improved, but insulating properties deteriorate due to higher voltage requiring enhanced insulation
Solution Approach 1:
The patent merges the insulating functions into a unified insulating structure that integrates multiple insulation components (insulating paint on wires, insulating sleeves on contacts, and insulating resin filling) to collectively address the insulation requirements of high-voltage operation, thereby maintaining reliability while enabling higher power output
Solution Approach 2:
The patent employs composite insulation solutions combining multiple materials with different insulating properties: enamel coating on copper wires, plastic or ceramic insulating sleeves on electrical contacts, and epoxy or polyurethane resin filling the stator cavity. This composite approach provides comprehensive insulation protection against high voltage breakdown
2Reliability
If complex insulating structures are added to improve insulation, then insulating properties are improved, but device complexity increases
Solution Approach 1:
The patent combines multiple insulating functions into an integrated insulating system where the insulating resin simultaneously provides electrical insulation, mechanical fixation of components, and environmental sealing, reducing the need for separate complex insulating structures
Solution Approach 2:
The patent uses uniform insulating resin material to fill the entire stator cavity, providing consistent insulation properties throughout the structure and simplifying the design compared to using different insulating materials in various locations
3Manufacturing precision
If manual assembly methods are used to ensure precision, then manufacturing precision is improved, but productivity deteriorates due to lower automation
Solution Approach 1:
The patent divides the stator into modular segments (stator core, windings, insulating components, and end caps) that can be manufactured separately with high precision using automated processes, then assembled together, enabling both precision and productivity
Solution Approach 2:
The patent replaces manual mechanical assembly with automated injection molding for the insulating resin and robotic welding for electrical connections, maintaining precision through programmable automation while dramatically increasing production speed
Data Source
AI summary
An electrical motor stator and a compressor includes a stator assembly and contact plate. The stator assembly includes an iron core; a winding having wires; a first insulating seat; and a plurality of first electrical contacts fixed to the first insulating seat. The contact plate includes a body; a plurality of sleeve seats having a first opening, a second opening, and a cavity extending between the first opening and the second opening. The sleeve seats are 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 includes 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. The second connecting portion is exposed on a side of the body.