Brushless Motor Stator Insulation for Higher Coil Stacking
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Solution Overview
Problem
Conventional brushless motors face challenges in improving the stacking factor of coils due to the increased distance between the teeth portion and the coil caused by the partial mold portion, which hinders efficient coil packing.
Innovation Solution
A stator design featuring insulation members with wider insulating plates that create a space between the coil and the teeth portion, allowing for improved coil stacking without the need for a bobbin, and a manufacturing method that includes attaching insulation members to stator blocks and winding coils around them to enhance alignment and bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a partial mold portion is used to attach the division core to the coil unit, then the gap between the coil unit and the division core is secured within an appropriate range, but the distance between the teeth portion and the coil increases, making it difficult to improve the stacking factor of the coil
Solution Approach 1:
The patent removes the partial mold portion from the structure and replaces it with a bobbinless design where the coil is directly attached to the teeth portion. This extraction eliminates the unnecessary intermediate component that was increasing the distance between the coil and teeth portion, thereby improving the stacking factor while maintaining gap securing through direct attachment
Solution Approach 2:
The patent merges the coil and teeth portion into a directly attached configuration, eliminating the separate partial mold portion. This merging reduces the overall distance and improves the stacking factor by allowing the coil to be positioned closer to the teeth portion while maintaining proper gap control through the bobbinless structure
Data Source
AI summary
A stator includes a plurality of stator blocks aligned in a circumferential direction and a plurality of coils each made of a winding wound around a corresponding one of the plurality of stator blocks. The stator includes a plurality of insulation members electrically insulating from the plurality of stator blocks from the plurality of coils for respective groups of the plurality of stator blocks and the plurality of coils. Each of the plurality of stator blocks includes a yoke portion located at its outermost perimeter and a teeth portion protruding from an inner peripheral surface of the yoke portion. Each of the plurality of insulation members includes a pair of insulating plates arranged to face each other across the teeth portion. Each of the pair of insulating plates has a width greater than a width of the teeth portion.