Polymer-Coated Electric Machine Component for Sharp-Edge Wire Protection
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Solution Overview
Problem
Existing electric machine components face challenges with manual and time-consuming processes for sealing and protecting electric lines due to perforated regions, sharp edges, and complex wiring, which lead to contamination risks and mechanical stress.
Innovation Solution
A polymer layer comprising cured plastic adhesive is applied to flat regions using a thermoplastic hot melt adhesive, forming a non-adhesive and non-porous network structure that adheres to the components without additional adhesives, covering electric lines and sharp edges to protect them from damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual sealing and protection processes are used for electric lines, then protection against contamination and mechanical stress is achieved, but production time and costs increase significantly
Solution Approach 1:
The patent replaces manual mechanical sealing processes with an automated polymer coating system. A polymer layer is applied as a continuous coating that automatically seals and protects electric lines, eliminating the need for manual intervention while maintaining protection against contamination and mechanical stress.
Solution Approach 2:
The polymer coating system provides self-service protection by automatically forming a protective layer that seals and protects electric lines without requiring subsequent manual operations. The coating process itself creates the protective function, eliminating the need for separate manual sealing steps.
2Reliability
If complex manual processes with masking and potting are used, then sealing quality is improved, but process complexity and preparation work increase
Solution Approach 1:
The patent extracts and eliminates the complex masking and potting steps from the sealing process. Instead of requiring multiple preparation and follow-up operations, the polymer coating system applies a protective layer directly to the electric lines and surrounding areas in a single operation, removing unnecessary process complexity while maintaining sealing quality.
Solution Approach 2:
The polymer coating serves multiple functions simultaneously: it seals apertures, protects against contamination, provides mechanical stress protection, and adheres to various surfaces. This multi-functional approach replaces the need for separate masking, potting, and protection steps with a single universal coating process.
3Reliability
If additional protective measures like edge-protection inserts are installed, then protection against sharp edges is improved, but manufacturing steps and costs increase
Solution Approach 1:
The patent merges the edge protection function with the polymer coating layer. The same polymer that provides sealing and contamination protection also serves as edge protection, eliminating the need for separate edge-protection inserts. The coating is applied in a way that automatically covers sharp edges and burrs on component surfaces.
Solution Approach 2:
The polymer coating material is designed to provide multiple protective functions simultaneously, including protection against sharp edges. The composite nature of the polymer layer combines sealing, contamination protection, and mechanical protection properties in a single material system, reducing the need for additional protective components.
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 solution simplifies the sealing and protection process, reducing manual labor and costs while effectively sealing apertures and protecting electric lines from contamination and mechanical stress, enhancing the reliability and efficiency of electric machine assembly.
Implementation Method 1
A polymer layer comprising cured plastic adhesive is applied to flat regions using a thermoplastic hot melt adhesive
Implementation Method 2
the polymer layer comprises cured plastic adhesive and adheres to the flat region
Data Source
AI summary
A component for an electric machine includes a flat region in which an electric line runs when the component is integrated into the electric machine and which includes a sharp-edged structure. A polymer layer adheres to the flat region without further aid such as to mask the sharp-edged structure and thereby protect from damage the electric line on the flat region. The polymer layer is made of cured plastic adhesive and jetted onto the flat region in the form of threads, such that the threads are spin-coated on top of one another in the form of overlapping loops and form a network structure which spans the sharp-edged structure.