Insulating Tubes for Motor Wire Electrical Isolation
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Solution Overview
Problem
Conventional methods for insulating conductor wires between coils in motors lack reliability, as they may not effectively prevent electrical exposure and can be prone to failure due to material weaknesses or improper sealing.
Innovation Solution
The use of continuous, heat-resistant, and electrically insulating tubes made from materials like fluorocarbon polymers or glass fibers, which are extruded or woven to cover the passage portions of conductor wires between coils, ensuring reliable electrical insulation by covering the entire passage without breaks or joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional insulation methods (tape winding with thermosetting resin) are used, then the insulation process is simple, but the reliability of electrical insulation is insufficient
Solution Approach 1:
The patent uses insulating tubes made from flexible materials such as fluorocarbon polymer sheets or glass fiber fabrics that are formed into tubular shapes. These flexible insulating tubes are slipped over the conductor wires during the coil winding process, providing reliable electrical insulation while maintaining ease of application. The flexible nature of these materials allows them to conform to the wire shape and withstand the winding process without breaking or losing insulation effectiveness.
2Reliability
If insulating tubes are used to cover conductor wires, then electrical insulation reliability is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The insulating tubes are prepared in advance and placed in position before the conductor wire is fully installed. During the coil winding process, the insulating tubes are slipped over the conductor wires as they pass through the winding area. This preliminary positioning allows the insulation to be applied continuously during normal manufacturing operations without requiring separate insulation steps, thereby maintaining ease of manufacture while ensuring reliable insulation coverage.
3Reliability
If continuous insulating tubes are used without breaks or joints, then insulation reliability is maximized, but the difficulty of finding suitable continuous materials increases
Solution Approach 1:
The patent employs insulating tubes formed from continuous fluorocarbon polymer sheets or glass fiber fabrics that can be manufactured in long continuous lengths. These material types are commercially available as continuous sheets or fabrics that can be formed into tubes without requiring joints or connections. The continuous nature of these materials ensures uninterrupted insulation coverage along the entire length of the conductor wire, maximizing insulation reliability while utilizing readily available industrial materials.
Data Source
AI summary
A motor includes a shaft, a rotor, a stator, and a housing. The stator preferably includes a core including a plurality of teeth, a plurality of coils, and electrically insulating tubes. The core is defined by a combination of a plurality of unit cores each of which has a separate one of the teeth. The plurality of coils include two or more continuous coils defined by a single line of a conductor wire. Each of the electrically insulating tubes is arranged to cover at least a portion of the conductor wire which passes between the continuous coils.