Modular Stator Segmentation for Thinner Insulation Walls
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing stator designs for electric motors face challenges in achieving thin insulation walls, particularly for longer stator cores, which results in reduced copper fill and decreased magnetic efficiency due to thicker insulating wall thicknesses caused by the plastic overmolding process.
Innovation Solution
A modular stator body composed of axially arranged stator cores with separate overmolding, where each core is formed from stacked electrical laminations and assembled in series using integrated connecting means, allowing for thinner overmolding layers and thinner insulating walls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single stator core is overmolded with plastic material, then the entire stator core is insulated, but the insulating wall thickness increases for longer stators
Solution Approach 1:
The stator core is divided into multiple individual cores that are overmolded separately and then assembled together. This segmentation allows each core to have a shorter flow path during overmolding, resulting in thinner insulating walls while maintaining adequate insulation quality. The modular approach enables better control over the overmolding process for each individual core.
2Reliability
If plastic overmolding is used for insulation, then the stator core is protected electrically, but the copper fill decreases due to thicker insulation walls
Solution Approach 1:
By segmenting the stator into multiple individually overmolded cores, the insulation wall thickness is reduced, which directly increases the available space for copper winding and improves copper fill. The segmented approach allows optimization of insulation thickness without compromising electrical insulation reliability.
3Reliability
If plastic overmolding is used for insulation, then the stator core is protected electrically, but magnetic efficiency decreases due to thicker insulation walls
Solution Approach 1:
The segmentation of the stator core into multiple individually overmolded units reduces the overall insulation wall thickness, thereby minimizing the impact on magnetic flux paths and improving magnetic efficiency while maintaining adequate electrical insulation.
4Length of stationary object
If a single long stator core is overmolded, then the flow path in the overmolding tool increases, but thinner insulating walls cannot be achieved
Solution Approach 1:
The long stator core is divided into multiple shorter individual cores that are overmolded separately. This segmentation reduces the flow path length in the overmolding tool for each individual core, enabling better control over insulating wall thickness and achieving thinner, more uniform insulation layers.
5Length of stationary object
If the stator core is divided into modular units, then thinner overmolding layers are achieved, but the device complexity increases
Solution Approach 1:
The stator is segmented into modular cores that are overmolded separately to achieve thinner insulation layers. While this increases manufacturing complexity, the modular design allows for standardized production of individual cores that can be efficiently assembled, and the benefits of reduced material usage and improved performance offset the increased assembly complexity.
Solution Approach 2:
The modular core design with standardized connecting means creates universal, interchangeable units that can be efficiently assembled. The connecting means serve multiple functions including mechanical attachment and alignment, reducing the overall complexity despite the modular approach.
Data Source
AI summary
A stator (1) for an electric motor has a modular stator body (2) with at least two stator cores (10, 20) arranged axially in series. Each core (10, 20) is form from a plurality of stacked electrical laminations (11, 21). This forms winding poles (16, 26) with radially extending winding webs (17, 27). The stator cores (10, 20) each have a separate overmolding (U1, U2).