Insulated Carrier Stack for Electric Machine Coils
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Solution Overview
Problem
Existing carriers for coils in electric machines lack effective electrical insulation and efficient heat dissipation, leading to reduced power density and increased installation space requirements.
Innovation Solution
A rotation-symmetrical carrier stack with laminations and axial slots, coated with electrically insulating material on slot walls and end faces, which can also be thermally conductive, to separate winding heads from the carrier and enhance heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrically insulating material is applied on slot walls and end faces, then electrical insulation is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple functions into the electrically insulating material layer: it provides electrical insulation for slot walls and end faces, serves as thermal management interface, and acts as structural support for winding heads. This merging of functions reduces the need for separate components, thereby improving reliability without proportionally increasing device complexity.
Solution Approach 2:
The electrically insulating material is designed to perform multiple roles simultaneously: electrical insulation, thermal conduction interface, mechanical support, and spacing maintenance. This multi-functionality allows a single component to address multiple requirements, resolving the contradiction between improved insulation and increased complexity.
2Temperature
If thermally conductive electrically insulating material is used, then heat dissipation is enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent specifies particular thermal conductivity parameters for the electrically insulating material, selecting materials with optimized thermal properties. By defining specific parameter ranges for thermal conductivity, the patent enables heat dissipation enhancement while maintaining manufacturability through standardized material selection criteria.
Solution Approach 2:
The use of composite materials that combine electrical insulation properties with enhanced thermal conductivity allows simultaneous achievement of both requirements. These composite materials are designed to provide the necessary thermal management performance while maintaining ease of application and manufacturing processes.
3Reliability
If electrically insulating material covers entire end face, then electrical insulation is improved, but installation space increases
Solution Approach 1:
The patent applies electrically insulating material selectively to specific areas where electrical insulation is critically needed, such as slot walls and portions of end faces adjacent to winding heads. This localized application approach provides adequate insulation protection while minimizing the overall material coverage and space occupation.
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 solution provides improved electrical insulation, reduced installation space, and enhanced power output by using electrically insulating and thermally conductive materials to manage heat effectively within the electric machine.
Implementation Method 1
electrically insulating material applied at least upon the slot walls of at least one of the end faces to cover the slot walls at their end face and to electrically insulate the slot walls
Implementation Method 2
the electrically insulating material can be thermally conductive. Thus, heat can be better dissipated from at least one of the end faces of the carrier stack
Data Source
AI summary
A carrier for coils of an electric machine includes a rotation-symmetrical carrier stack having laminations with axial slots which are configured to receive a wire of the coils. Adjacent ones of the slots are separated from one another by a slot wall. The carrier stack has circular end faces and is formed with slot openings for the slots. Electrically insulating material is applied upon at least the slot walls of at least one of the end faces to cover the slot walls at their end face and to electrically insulate the slot walls.