Dual-Molded Flat Coil Assembly for Simpler Stator Manufacturing
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Solution Overview
Problem
The existing stator manufacturing process for hybrid and electric vehicles is complex, involving multiple steps such as straightening, forming, coating, and inserting insulation sheets, which reduces manufacturing efficiency and increases costs.
Innovation Solution
A coil assembly with unit flat coils and a molding body formed by dual injection molding, where the molding body partially surrounds the coils, eliminating the need for separate insulation sheets and coating film removal processes, and allowing for heat treatment to ensure extensibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a flat coil is used to maximize space factor and minimize dead space, then the motor output is improved and size is reduced, but the manufacturing process becomes complicated requiring multiple steps including straightening, forming, coating removal, cutting, welding, and insulation sheet insertion
Solution Approach 1:
The patent combines the flat coil and insulation sheet into a single integrated component. The insulation function is merged directly into the coil structure through a coating layer applied during the coil forming process, eliminating the need for separate insulation sheets and reducing the number of manufacturing steps while maintaining the space-efficient flat coil design
Solution Approach 2:
The insulation coating is applied to the flat coil during the forming process itself, before the coil is installed in the motor. This preliminary application of insulation eliminates the need for subsequent insulation sheet insertion steps, simplifying the manufacturing process while preserving the compact flat coil configuration
2Ease of manufacture
If multiple manufacturing steps including coating film removal are used, then the flat coil can be formed and assembled, but the manufacturing efficiency deteriorates and production time increases
Solution Approach 1:
The patent extracts and eliminates the coating removal step from the manufacturing process. By using a coating material that remains intact and functional throughout the assembly process, the need for laser-stripping or other removal operations is completely removed, significantly improving manufacturing efficiency while maintaining coil formation capability
Solution Approach 2:
The coating layer on the flat coil serves multiple functions simultaneously: it provides insulation, protects the conductor, and remains in place during assembly without requiring removal. The coating performs its insulating function self-sufficiently throughout the entire manufacturing and operation process, eliminating the need for separate removal and replacement steps
3Reliability
If separate insulation sheets are manufactured and inserted, then insulation is provided, but the structure becomes more complicated and assembly process is lengthened
Solution Approach 1:
The insulation function is merged with the coil structure itself through a coating layer applied during manufacturing. This integration eliminates separate insulation sheets and their associated insertion steps, reducing structural complexity while maintaining reliable insulation performance through the combined coil-coating assembly
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 approach simplifies the stator structure and manufacturing process, improves assembly properties, reduces costs, and enables stable integration of flat coils without damaging the coating film, while allowing for flexible design modifications.
Implementation Method 1
a molding body including a structure formed in dual injection molding and configured to partially surround the plurality of unit flat coils
Implementation Method 2
allow a heat treatment (annealing) process for ensuring extensibility of a flat coil
Data Source
AI summary
The present disclosure relates to a coil assembly including: a plurality of unit flat coils disposed and spaced apart from one another in a circumferential direction; and a molding body made by dual injection molding and configured to partially surround the unit flat coils, thereby simplifying a structure of the coil assembly and a process of manufacturing the coil assembly.