Encapsulated Stator Jacket Segmentation for Air Gap and Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional encapsulated stators face issues with air gaps between the permanent magnet and pole plates due to thick encapsulants, leading to poor operational efficiency and safety risks, while thin encapsulants compromise waterproof and moisture-proof effects.
Innovation Solution
An encapsulated stator design featuring a driving module with a silicon steel plate unit, a jacket mounted around the module, and an encapsulant that partially covers the jacket's outer face, ensuring sufficient air gaps and enhanced sealing by bonding the encapsulant to the module, jacket, and shaft tube.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the encapsulant has a large thickness to provide enhanced waterproof and moisture-proof effects, then the sealing performance is improved, but the air gaps between the permanent magnet and pole plates become too small leading to poor operational efficiency and safety risks
Solution Approach 1:
The encapsulation structure is segmented into multiple functional layers: a first encapsulant layer providing waterproof sealing, and a second encapsulant layer forming air gaps for safety. This segmentation allows each layer to fulfill its specific function without compromising the other, resolving the contradiction between sealing thickness and operational safety.
Solution Approach 2:
The first encapsulant layer acts as an intermediary between the driving module and the external environment, providing waterproof sealing while allowing the second encapsulant layer to create the necessary air gaps. This intermediary structure enables both waterproof protection and operational efficiency to coexist.
2Loss of energy
If the encapsulant has a small thickness to maintain air gaps for safe motor operation, then operational efficiency is improved, but the waterproof and moisture-proof effects are adversely affected
Solution Approach 1:
The encapsulation is divided into functional segments where the first encapsulant layer handles waterproofing while the second layer maintains air gaps. This segmentation allows thin overall encapsulation while preserving both waterproof performance and operational safety through specialized functional zones.
3Ease of manufacture
If a separation sleeve is mounted around the stator to facilitate mold-removing operation, then ease of manufacture is improved, but the air gaps between the permanent magnet and stator are decreased resulting in safety risks
Solution Approach 1:
The separation sleeve function is extracted and replaced by the molded cavity structure of the encapsulant itself. The encapsulant is formed with built-in separation features during molding that facilitate easy removal without requiring additional separation sleeves, thus maintaining ease of manufacture while preserving air gaps for safety.
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 design maintains efficient air gaps for safe motor operation while providing enhanced waterproof and moisture-proof effects, ensuring reliable performance and safety.
Implementation Method 1
An encapsulant is bonded to the driving module, the jacket, and the shaft tube. The encapsulant encapsulates the driving module.
Implementation Method 2
When the motor stator is energized to create an alternating magnetic field that is induced by the permanent magnet, the magnetic lines of force created by the permanent magnet pass through the air gaps and interact with the motor stator to generate flux linkage, driving the rotor to rotate.
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
An encapsulated stator includes a driving module (11) coupled to a shaft tube. The driving module (11) includes a silicon steel plate unit (111). A coil unit (112) is wound around the silicon steel plate unit (111). A jacket (12) is mounted to an outer periphery of the silicon steel plate unit (111) of the driving module (11). The jacket (12) includes an inner face (12a) and an outer face (12b) opposite to the inner face (12a). The inner face (12a) of the jacket (12) faces the driving module (11). An encapsulant (13) is bonded to the driving module (11), the jacket (12), and the shaft tube. The encapsulant (13) encapsulates the driving module (11). The encapsulant (13) partially encapsulates the outer face (12b) of the jacket (12).