U-Shaped Insulating Clip for Stator Winding Overhangs
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Solution Overview
Problem
Existing methods for insulating stator winding overhangs in electrical machines using flat pack technology face challenges with complex process technology and non-uniform adhesion of bonded insulating materials, leading to mechanical stress and damage during bending and insertion.
Innovation Solution
A self-clamping insulating element with spring-elastic legs, preferably made of electrically insulating plastic, is designed to securely attach to stator winding overhangs, providing enhanced mechanical protection and insulation without additional elements, using a U-shaped profile with reinforced transition areas and optional holding elements for secure clamping and damage prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bonded insulating material is applied to stator winding overhangs, then electrical insulation is provided, but the process technology becomes very complex and uniform adhesion becomes problematic
Solution Approach 1:
The patent uses a simple, inexpensive insulating sleeve made of thermoplastic material that can be easily applied and discarded if necessary, replacing complex bonded insulating materials. The sleeve provides sufficient insulation without requiring sophisticated bonding processes or materials.
Solution Approach 2:
The patent changes the physical state of the insulating material from bonded (permanent) to thermoplastic (heat-formable). By heating the thermoplastic sleeve above its glass transition temperature, it becomes soft and moldable, allowing easy attachment to the winding overhangs, then cools to provide rigid insulation.
2Reliability
If bonded insulating material is applied to stator winding overhangs, then electrical insulation is provided, but adhesion uniformity becomes problematic
Solution Approach 1:
The insulating sleeve is a simple, self-contained component that does not rely on bonding processes. It is slipped over the winding overhangs and secured through friction and heat deformation, eliminating adhesion uniformity issues entirely.
Solution Approach 2:
The thermoplastic sleeve is self-adhering through its material properties. When heated, it softens and conforms to the winding shape, then cools to lock in place, providing uniform insulation without requiring external bonding agents or processes.
3Ease of operation
If insulating element with spring-elastic legs is used, then ease of attachment is improved, but device complexity increases
Solution Approach 1:
The insulating element features spring-elastic legs that automatically clamp onto the winding overhangs when the element is compressed during installation. The elastic deformation provides self-clamping force, eliminating the need for screws, clips, or other fastening mechanisms.
Solution Approach 2:
The insulating element uses dynamic elastic deformation of its legs to achieve attachment. The legs are designed with specific spring constants that allow them to flex during installation and then maintain constant clamping force, adapting to variations in winding dimensions.
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 ensures high reliability and ease of attachment for electrical insulation and mechanical protection of winding wires, preventing damage during bending and insertion, while maintaining a high holding force and defined positioning within stator slots.
Implementation Method 1
The insulating element can be plugged onto at least one overhang of the stator winding with its spring-elastic side legs in a self-clamping manner
Data Source
Figure 1~2
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AI summary
The invention relates to an insulating element for the stator winding (5) of an electric machine, in the case of which electric machine the stator (9) is produced from a flat core (1) having a stator winding (5) lying therein and having winding wires (6) protruding from the flat core (1), which winding wires form at least one winding projection (8), wherein the insulating element (14) is an insulating clip (17-19) that can be placed onto the winding wires (6) of a winding projection (8) that protrude from the flat core (1) and that has a substantially U-shaped cross-section and elastic side legs (15, 16), and, in the relaxed state, the insulating clip (17-19) has an opening width at the free end of the lateral legs (15, 16) of the insulating clip that is smaller than the thickness of a winding projection (8) to be inserted between the legs (15, 16).