Insulating Member Flange Design for Coil Retention
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Solution Overview
Problem
Conventional insulating members between a core body and a coil face challenges in dimensional control and formability due to complex shapes, leading to resin flow issues and material inefficiencies, which are not adequately addressed by existing configurations.
Innovation Solution
An insulating member with a substantially rectangular wound portion and a flange having corner portions and intermediate sections of varying widths, a curved tip, and a thickness that tapers from root to tip, enhancing retention capability, formability, and heat conductivity while reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulating member has a complex shape to secure coil retention capability, then the retention capability is improved, but dimensional control becomes difficult and formability deteriorates
Solution Approach 1:
The flange is segmented into corner portions and intermediate portions with different widths. The corner portions have larger widths to secure coil retention capability, while the intermediate portions have smaller widths to improve dimensional control and formability. This segmentation allows different regions to serve different functions, resolving the contradiction between retention capability and manufacturing precision.
Solution Approach 2:
Different portions of the flange are given different local qualities (widths). The corner portions are designed with larger widths specifically for coil retention, while intermediate portions have narrower widths for better dimensional control and resin flow. This local differentiation enables the insulating member to simultaneously achieve both retention capability and manufacturing precision.
2Reliability
If the insulating member has a complex shape to secure coil retention capability, then the retention capability is improved, but formability deteriorates due to resin flow issues
Solution Approach 1:
The flange is divided into corner portions and intermediate portions. The intermediate portions with smaller widths create pathways for resin flow during molding, improving formability. The corner portions maintain larger widths to ensure coil retention. This segmentation resolves the contradiction between retention capability and formability.
Solution Approach 2:
The tip of the flange is designed with a curved shape rather than a sharp angle. This curvature facilitates resin flow into the mold cavity during molding, improving formability while maintaining the necessary retention capability through the corner portions.
3Strength
If the flange has uniform thickness to maintain strength, then strength is improved, but material usage increases leading to higher cost and weight
Solution Approach 1:
The flange thickness is varied locally rather than being uniform. The root portion has greater thickness to provide strength and structural support, while the tip portion has reduced thickness to minimize material usage. This local differentiation maintains necessary strength while reducing weight and material cost.
Solution Approach 2:
Instead of providing uniform excessive thickness throughout the flange, the design applies sufficient thickness only where structurally necessary (at the root), and reduces thickness where less support is needed (at the tip). This partial application of thickness maintains strength while minimizing material usage.
4Strength
If the flange has uniform thickness to maintain strength, then strength is improved, but manufacturing cost increases due to excessive material usage
Solution Approach 1:
The flange thickness is optimized locally with greater thickness at the root for strength and reduced thickness at the tip to minimize material usage. This local differentiation reduces manufacturing cost by eliminating excessive material while maintaining necessary strength through strategic thickness distribution.
Data Source
AI summary
An insulator is provided between a stator core and a conductive wire provided on the stator core. The insulator includes a wound portion, around which the conductive wire is wounded, having a substantially rectangular shape; and a flange, formed in the axial end of the wound portion in the stator tooth tip side, for pressing the conductive wire in the axial direction (radial direction relative to the rotation axis of a rotor in a configuration of a rotating electrical machine). The flange includes four corner portions at its four corners, and intermediate portions formed between the four corner portions to have a width (B2) narrower than the width (B1) of the four corner portions. In addition, the flange has a tip with a curved shape.