Motor Stator Insulator Fixing Structure Without Adhesive
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Solution Overview
Problem
Conventional stators face challenges in achieving a stable fixing force due to variations in adhesive injection amounts and adhesive deterioration over time, which affects the reliability and performance of the motor.
Innovation Solution
The stator design incorporates a stator core with annular shape, tooth portions, insulators with bosses, and covers that fit over the insulators, eliminating the need for adhesives by using a boss-and-fixing-hole mechanism to secure the insulators to the stator core, thereby enhancing stability and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is used to bond insulator to stator core, then insulator can be fixed to tooth portions, but fixing force becomes unstable due to adhesive injection amount variations and adhesive deterioration
Solution Approach 1:
The patent removes the adhesive bonding process entirely and replaces it with a mechanical interference fit system. The insulator includes a protrusion that fits into a corresponding recess in the stator core, eliminating the need for adhesive application while providing stable, durable mechanical fixation that does not deteriorate over time.
Solution Approach 2:
The patent replaces the chemical bonding mechanism (adhesive) with a mechanical interference fit system. The protrusion-recess geometry creates direct mechanical engagement between the insulator and stator core, providing reliable fixation through physical interlocking rather than chemical adhesion.
2Ease of manufacture
If adhesive is used to fix insulator, then insulator can be secured to tooth portions, but manufacturing precision deteriorates due to variations in adhesive injection amount
Solution Approach 1:
The patent eliminates the adhesive application step from the manufacturing process, replacing it with a precision-machined protrusion-recess interface. This mechanical system provides consistent positioning accuracy without being affected by variations in adhesive injection amount or application technique.
Solution Approach 2:
The patent substitutes the variable chemical bonding process with a controlled mechanical interference fit. The geometric relationship between the protrusion and recess ensures precise and repeatable positioning of the insulator relative to the stator core, independent of operator skill or adhesive quality.
3Duration of action of stationary object
If adhesive is used for bonding, then insulator can be attached to stator core, but reliability decreases due to adhesive deterioration in use environment
Solution Approach 1:
The patent removes the adhesive layer from the bonding interface, replacing it with a direct mechanical interference fit between the insulator protrusion and stator core recess. This eliminates the deterioration issue inherent in adhesive materials exposed to temperature, humidity, and mechanical stress during motor operation.
Solution Approach 2:
The patent replaces the time-dependent chemical bond with a stable mechanical interference fit. The geometric interlocking provides durable fixation that maintains its strength throughout the motor's operational life, unaffected by environmental factors that cause adhesive deterioration.
Data Source
AI summary
A stator includes a stator core that includes a core back portion having an annular shape and with a central axis as a center and tooth portions extending from the core back portion to an inside in a radial direction and arranged in a circumferential direction, insulators that are attached to the tooth portions from the inside in the radial direction, a coil that is wound around the insulator, and a cover that supports an inner surface of the insulator opposing the inside in the radial direction from the inside in the radial direction.