Plastic-Packaged Stator with Embedded Lug Bosses
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Solution Overview
Problem
Conventional stators are costly, inefficient, and prone to structural integrity issues and failure during long-term use.
Innovation Solution
A plastic-packaged stator design featuring a sleeve base, tooth assemblies with laminated silicon steel sheets, terminal insulators, and coil windings, integrated with a plastic body that includes lug bosses, bulges, notches, and a Hall plate assembly for enhanced structural integrity and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional stator production methods are used, then manufacturing processes are established, but production cost is high and structural integrity is low
Solution Approach 1:
The patent combines multiple stator components (sleeve base, tooth assemblies, coil windings, terminal insulators, and plastic packaging) into an integrated structure. The plastic-packaged body unifies these elements, eliminating separate assembly steps and reducing production costs while enhancing structural integrity through the composite plastic-metal construction.
Solution Approach 2:
The patent employs composite materials by integrating metal components (iron core with silicon steel sheets, sleeve base) with plastic packaging material. This composite structure provides both the electrical and mechanical properties of metal and the protective, cost-effective characteristics of plastic, resolving the contradiction between reliability and manufacturing cost.
2Reliability
If conventional stator design is used, then basic functionality is achieved, but structural intensity is low leading to failure during long-term use
Solution Approach 1:
The plastic-packaged body merges the protective function of packaging with the structural function of the stator housing. This integration creates a unified structure that maintains structural intensity while providing long-term protection against environmental factors, thereby improving reliability without compromising strength.
Solution Approach 2:
The plastic-packaged body acts as a protective shell that encapsulates and protects the internal metal components. This flexible yet durable plastic shell enhances the overall structural intensity and protects against corrosion and mechanical damage, ensuring long-term reliability.
3Ease of manufacture
If conventional stator production is used, then standard assembly is achieved, but material usage is excessive and waste is generated
Solution Approach 1:
By merging the packaging function with the structural function into a single plastic-packaged body, the patent eliminates the need for separate packaging materials and reduces excess material usage. The integrated design maintains assembly simplicity while minimizing material waste through precise material placement and elimination of redundant components.
4Quantity of substance
If conventional stator design is used, then basic structural requirements are met, but production cost increases due to material usage
Solution Approach 1:
The use of composite materials (plastic and metal) allows the patent to reduce the quantity of expensive metal materials while maintaining structural requirements. The plastic components provide structural support at lower cost, reducing overall material consumption and production cost without compromising manufacturing ease.
Data Source
AI summary
A plastic-packaged stator includes a sleeve base, a plurality of tooth assemblies, and a plastic-packaged body. Each tooth assembly includes an iron core including a plurality of laminated silicon steel sheets, a terminal insulator, and coil windings. The terminal insulator is disposed on one end of the iron core. The coil windings are coiled on the terminal insulator. A plurality of lug bosses is circumferentially disposed at intervals on the outer wall surface of the sleeve base. An inner end of the iron core includes slots. The tooth assemblies are circumferentially disposed on the outer wall surface of the sleeve base. The lug bosses are embedded in the slots. The plastic-packaged body integrates the sleeve base with the tooth assemblies.