Insulating Member With Exposed Adhesive Sections For Rotary Electric Machine Slots
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Solution Overview
Problem
Conventional methods for inserting insulating members into slots in rotary electric machines often result in adhesive peeling off and generating foreign matter, leading to assembly failures.
Innovation Solution
An insulating member with an adhesive layer having exposed sections that extend in the axial direction, preventing contact with slot edges and peeling, and featuring front and back symmetry for easy insertion and use without distinguishing between sides, along with a lubricating layer for smooth insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is disposed on both main surfaces of the insulating member to fix the stator core and coil, then fixing reliability is improved, but the adhesive may contact the slot edge and peel off during insertion, generating foreign matter
Solution Approach 1:
The adhesive layer is designed with non-uniform thickness, creating a thicker section and a thinner section. The thicker section provides sufficient adhesive strength for reliable fixing, while the thinner section prevents contact with the slot edge during insertion, eliminating foreign matter generation. This local variation in adhesive layer quality resolves the contradiction between fixing reliability and foreign matter prevention.
2Ease of manufacture
If varnish is poured into the slot to fix the stator core and coil, then fixing is achieved, but the varnish flows out from one end and is discarded, increasing manufacturing cost
Solution Approach 1:
The adhesive is pre-applied to the insulating member in a controlled manner before assembly, with specific thickness variations built into the adhesive layer structure. This preliminary preparation ensures that the adhesive remains contained within the slot during insertion and curing, preventing overflow and material waste, thereby reducing manufacturing costs.
3Reliability
If the insulating member is inserted into the slot with adhesive on both surfaces, then insulation is provided, but the adhesive peels off at the slot edge, causing assembly failure
Solution Approach 1:
The adhesive layer is designed with a thinner section at the region that contacts the slot edge during insertion. This localized thickness reduction prevents adhesive peeling at the critical edge contact point, ensuring assembly precision is maintained while preserving insulation reliability through the thicker adhesive sections.
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
Prevents adhesive peeling and foreign matter generation during manufacturing, reducing assembly failures and ensuring proper assembly of rotary electric machines.
Implementation Method 1
an adhesive layer which is provided on at least one of the first surface and the second surface of the insulating base material and formed of an adhesive
Implementation Method 2
a lubricating layer formed of a lubricant be provided on at least one of the first surface and the second surface of the insulating base material in the exposed section
Data Source
AI summary
An insulating paper (40) is inserted into a slot (13) of a stator core (10) of a rotary electric machine and insulates between the stator core (10) and a stator coil (20) disposed in the slot (13). An insulating member (40) comprises a sheet-shaped insulating base material (50), and a first adhesive layer (60A) which is provided on a first surface (50a) of the insulating base material (50) and which is formed of an adhesive. The first adhesive layer (60A) is provided with an exposed section (61) which extends in the axial direction of the stator core (10) and in which the insulating base material (50) is exposed from the adhesive.