Hairpin Stator Core Insulation Layer for Heat Dissipation
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Solution Overview
Problem
Conventional stator cores for motors face challenges in heat dissipation and productivity due to the insertion of insulation paper into hairpin inserting holes, which increases unit costs and decreases motor performance.
Innovation Solution
A stator core design that forms an insulation layer on the inner circumferential surface of the hairpin inserting hole without using insulation paper, and integrally fixes a laminated core using embossings formed in the lamina members and the insulation layer, without the need for adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation paper is inserted into the hairpin inserting hole to increase dielectric strength, then insulation performance is improved, but unit cost increases and productivity decreases due to the additional insertion process
Solution Approach 1:
The patent combines the insulation layer and the hairpin inserting hole formation into a single integrated structure. The insulation layer is formed directly on the inner circumferential surface of the hairpin inserting hole through coating or deposition processes, eliminating the need for separate insulation paper insertion. This merging of functions maintains dielectric strength while simplifying the manufacturing process and improving productivity
Solution Approach 2:
The patent extracts the insulation function from the separate insulation paper component and integrates it directly into the hairpin inserting hole structure itself. By forming the insulation layer as an inherent part of the hole structure rather than as a separate inserted component, the design eliminates the additional insertion process while maintaining the required insulation performance
2Reliability
If insulation paper is inserted into the hairpin inserting hole to increase dielectric strength, then insulation performance is improved, but unit cost increases due to additional materials and processes
Solution Approach 1:
The patent merges the insulation layer formation with the hairpin inserting hole creation process. By applying the insulation layer directly during or immediately after hole formation through coating or deposition methods, the design eliminates the need for separate insulation paper materials and insertion operations, thereby reducing unit cost while maintaining dielectric strength
Solution Approach 2:
The patent replaces the expensive and labor-intensive insulation paper with a more economical insulation layer formed through efficient coating or deposition processes. This substitution uses less material and requires simpler application methods, reducing overall manufacturing costs while achieving the same insulation function
3Reliability
If insulation paper is inserted into the hairpin inserting hole, then dielectric strength is increased, but heat dissipation performance deteriorates due to the insulation paper barrier
Solution Approach 1:
The patent applies the insulation layer with controlled thickness and material properties specifically on the inner circumferential surface of the hairpin inserting hole. By optimizing the local insulation characteristics rather than using thick insulation paper throughout, the design maintains sufficient dielectric strength at the critical insulation interface while allowing better thermal conduction pathways for heat dissipation
Solution Approach 2:
The patent uses composite material structures where the insulation layer is formed from materials that provide both adequate dielectric strength and improved thermal conductivity compared to traditional insulation paper. This composite approach allows simultaneous achievement of electrical insulation and heat dissipation requirements
4Stability of the object's composition
If embossing is formed in the lamina member through punching process to fix laminated core, then structural integrity is improved, but residual stress is generated and plastic deformation occurs
Solution Approach 1:
The patent performs preliminary forming of the embossing structure and insulation layer before final assembly and lamination. By pre-forming these features, the design reduces the need for high-force punching operations during final assembly, thereby minimizing plastic deformation and residual stress generation in the lamina members
Data Source
AI summary
The present disclosure relates to a stator core for a motor capable of improving heat dissipation. Disclosed is a stator core for a motor, including: a laminated core formed by laminating a plurality of lamina members having an embossing formed along a circumferential direction on a radial outside thereof; and an insulation layer having a certain thickness and formed on an inner circumferential surface of a hairpin inserting hole, the hairpin inserting hole formed along a circumferential direction on a radial inside of the laminated core. With this configuration, there is an effect of improving quality of the motor as the productivity and heat dissipation is improved by forming the insulation layer without inserting the insulation paper into the hairpin inserting hole.