Motor Stator Insulation and Coupling Design
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Solution Overview
Problem
Conventional stators for motors face issues such as increased steel consumption, scrap generation, high manufacturing costs, and inadequate electromagnetic characteristics due to complex insulation methods and separate molds, which limit coil turns and increase plastic resin usage.
Innovation Solution
A stator design featuring a circular base with radially formed teeth, an insulating layer coating the entire surface except the inner peripheral surface and first holes, and coupling parts with bush and bracket structures that reduce material usage and enhance rigidity, using a two-layer insulating coating with adhesive and insulating resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If coupling parts are formed every steel plate by punching and laminating, then the stator core and coupling parts can be completed, but the quantity of steel plate consumed increases and scrap is generated
Solution Approach 1:
The invention separates the coupling parts from the stator core structure. Instead of forming coupling parts by punching holes in each steel plate, the patent uses a continuous stator core made by laminating steel plates, and attaches separate coupling parts (formed from other materials like plastic or aluminum) to the stator core. This segmentation eliminates the need to punch holes through multiple steel plates, reducing steel consumption and scrap generation while maintaining the functionality of both the stator core and coupling parts.
2Reliability
If upper and lower insulators are coupled to the stator core, then insulation is provided, but the slots between teeth are reduced in size limiting coil turns and electromagnetic characteristics
Solution Approach 1:
The invention merges the insulation function with the stator core structure itself. Instead of adding separate upper and lower insulators that occupy space in the slots, the patent applies insulation coating directly to the stator core surface, including the slot regions. This integrated approach provides necessary insulation while preserving the full slot volume for coil windings, thereby maintaining electromagnetic characteristics and allowing sufficient coil turns.
3Ease of manufacture
If L-shaped coupling parts are attached to the stator core, then coupling is achieved, but insulating powder must be coated on the entire surface increasing consumption
Solution Approach 1:
The invention applies insulation coating selectively rather than uniformly coating the entire stator core surface with insulating powder. The patent uses a liquid insulation coating that is applied only to specific areas requiring insulation, such as the outer surface and certain internal surfaces, while leaving other areas (like the slot regions) uncovered or minimally coated. This localized insulation approach reduces insulating powder consumption while still providing adequate insulation where needed, complementing the L-shaped coupling parts.
4Ease of manufacture
If L-shaped coupling parts are attached by welding, then coupling is achieved, but rigid coupled result is not ensured
Solution Approach 1:
The invention employs composite construction for the coupling parts, combining different materials with complementary properties. The coupling parts are formed from materials such as plastic or aluminum that can be securely attached to the stator core through mechanical means like press-fitting or riveting, rather than welding. This composite approach ensures rigid coupling while avoiding the weaknesses of welding (such as heat distortion or weak welds), and the different materials work together to provide both structural integrity and electrical insulation.
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
This design simplifies the manufacturing process, reduces costs, and improves electromagnetic performance by minimizing material consumption and ensuring accurate coupling, while maintaining insulation effectiveness.
Implementation Method 1
an insulating layer coated on the entire surface of the stator core except the inner peripheral surface of the base and the plurality of first holes of the base
Data Source
AI summary
The present invention relates to a stator for a motor including: a stator core having a circular base along which a plurality of first holes is formed vertically and a plurality of teeth formed radially around the outer peripheral surface of the base; and an insulating layer coated on the entire surface of the stator core except the inner peripheral surface of the base and the plurality of first holes of the base.