Helical Flat-Conductor Coil Spacing for Heat Dissipation and Insulation
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Solution Overview
Problem
Existing coils used in motors, particularly those for electric vehicles, face limitations in heat dissipation performance and voltage resistance, necessitating improvements to enhance these critical characteristics.
Innovation Solution
A coil with a helical structure made from strip-shaped flat conductors, where each turn is separated by a preset interval and covered with an injection-molded resin, is developed. This design includes a stator with teeth arranged in an annular shape, where the coil is directly attached, and a motor incorporating this coil configuration to improve heat dissipation and voltage resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If flat conductors are continuously joined into a helical form to form a coil, then the space factor in the core is enhanced, but the heat dissipation performance and voltage resistance are insufficient
Solution Approach 1:
The continuous helical coil is segmented by introducing gaps between adjacent turns. These gaps divide the helical structure into discrete sections, allowing for improved heat dissipation and voltage resistance while maintaining the space-efficient helical configuration. The gap portion separates the first turn from the second turn, creating distinct electrical and thermal zones.
Solution Approach 2:
An insulating structure is introduced as an intermediary element between adjacent turns of the helical coil. This insulating structure serves multiple functions: it provides electrical insulation to enhance voltage resistance, creates physical separation for heat dissipation, and maintains the geometric spacing between turns. The insulating structure acts as a mediator that resolves the contradiction between maintaining tight spacing for space factor and creating separation for thermal and electrical performance.
2Quantity of substance
If the coil is formed by welding flat conductors to create a helical structure, then the space factor is improved, but the welded portions may deteriorate in properties
Solution Approach 1:
The welding process is extracted or removed from the coil formation process. Instead of welding flat conductors to create the helical structure, the patent uses a gap-based design where adjacent turns are separated by insulating structures. This eliminates the welded portions that are prone to property deterioration, while still achieving the desired helical configuration and space factor enhancement.
3Reliability
If high heat dissipation and voltage resistance are required for motors in electric vehicles, then existing coil designs are insufficient, but increasing separation between turns reduces space factor
Solution Approach 1:
The insulating structure is applied locally at specific positions where gaps are needed between turns, rather than uniformly throughout the entire coil. This localized application provides the necessary heat dissipation and voltage resistance enhancement only where required, while maintaining tight spacing and high space factor in other regions of the coil. The local quality approach allows differential treatment of different parts of the coil structure.
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 proposed coil design significantly enhances heat dissipation performance and voltage resistance, leading to improved motor efficiency and reliability, particularly in high-demand applications like electric vehicles, while also simplifying manufacturing and reducing component costs.
Implementation Method 1
Each turn of the helical structure body is covered with an injection-molded resin
Data Source
AI summary
Provided are a coil capable of enhancing heat dissipation performance and/or voltage resistance, and a stator and a motor using the coil.A coil includes a helical structure body made of strip-shaped flat conductors that are continuously joined into a helical form. In the helical structure body, a first turn of helix is separated from a second turn, which is continuous to the first turn, at a preset interval.