Motor Stator Insulation Structure for High-Voltage Vehicular Compressors
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Solution Overview
Problem
The increasing input voltage of motors in electric vehicles and the conductive nature of coolant and oil in vehicular compressors pose higher insulation requirements for motor stators, which existing technologies have not adequately addressed.
Innovation Solution
A motor stator design featuring insulated end plates and a wiring board with casing portions that form pouring cavities for insulating material, enhancing insulation by covering exposed conducting cores and connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the motor operates at high input voltage (e.g., 800V), then the power and performance of the motor is improved, but the insulation performance requirement worsens due to conductivity of coolant and oil environment
Solution Approach 1:
The patent applies preliminary action by pre-defining insulated treatment positions on the end plate before final assembly, and by designing the wiring board with integrated pouring cavities that are ready to receive insulating material. This preliminary preparation ensures that insulation treatment is systematically implemented at all critical locations before the motor operates in the high-voltage coolant/oil environment, preventing electrical leakage proactively
Solution Approach 2:
The patent introduces insulating material as an intermediary substance that fills the pouring cavities and covers the insulated treatment positions. This insulating material acts as a mediator between the conductive coolant/oil environment and the electrical components, blocking electrical leakage while allowing thermal exchange, thus enabling high-power operation in the challenging environment
2Reliability
If insulated treatment positions are provided on the end plate and pouring cavities are formed, then the insulation performance is improved, but the device complexity increases
Solution Approach 1:
The patent merges the wiring board with the pouring cavity structure, where the wiring board itself forms the pouring cavity through its design. This integration eliminates the need for separate cavity-forming components, reducing part count while maintaining the insulation function. The wiring board simultaneously serves as both an electrical connection component and an insulation containment structure
Solution Approach 2:
The end plate with insulated treatment positions serves multiple functions: it provides structural support for the stator core, creates defined pouring cavities for insulating material, and establishes insulated treatment positions for wire connections. This multi-functionality reduces the need for additional dedicated insulation components, simplifying the overall structure while enhancing insulation performance
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
The design provides improved insulation performance, ensuring stable operation in high-voltage and conductive environments, facilitating automatic production and reducing leakage risks.
Implementation Method 1
the insulating material is poured into the respective pouring cavity and solidified to cover the insulated treatment position
Data Source
AI summary
A motor stator, a motor, and a vehicular compressor. The motor stator includes a stator core; a first insulated end plate and a second insulated end plate mounted at opposite end surfaces of the stator core; a wire wrapping around the stator core and the first and second insulated end plates, the wire having a conducting core and an insulated outer sheath; and a wiring board mounted to an axial outer side of the first insulated end plate. The first insulated end plate includes a plurality of insulated treatment positions and the wiring board includes a plurality of casing portions through which the insulated treatment positions can be accessed for providing insulation material.