Single Resin Composition for Dynamo-Electric Machine Coil Insulation and Fixing
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Solution Overview
Problem
The existing technologies for dynamo-electric machines require two different resin compositions for insulation and coil fixing, necessitating two manufacturing equipment setups, which complicates the manufacturing process.
Innovation Solution
A single resin composition comprising a base unsaturated-polyester resin or vinyl-ester resin, a radical-polymerizable monomer with adhesiveness, a thermally latent isocyanate group, and a photo-radical polymerization initiator is used for both insulation coating and coil fixing, simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two different resin compositions are used for insulation and coil fixing, then insulating property and coil fixing property are improved, but manufacturing complexity increases
Solution Approach 1:
The patent develops a single resin composition that performs multiple functions: it provides electrical insulation, bonds coil ends to each other and to the core, and offers mechanical strength. This multi-functional resin eliminates the need for separate insulation resin and bonding resin applications, thereby simplifying manufacturing equipment while maintaining reliable insulating and fixing properties
Solution Approach 2:
The invention merges the functions of two separate resin compositions (insulation resin and bonding resin) into a single unified resin formulation. By combining the insulating characteristics with the bonding and fixing characteristics in one material, the patent reduces the number of manufacturing steps and equipment required, directly addressing the complexity issue
2Reliability
If two different resin compositions are used for insulation and coil fixing, then insulating property and coil fixing property are improved, but productivity decreases
Solution Approach 1:
The single resin composition is designed to simultaneously provide insulation, bonding, and fixing functions in one application step. This eliminates the sequential process of applying different resins, reducing manufacturing time and improving productivity while maintaining the reliable performance characteristics of both insulation and coil fixing
Solution Approach 2:
The patent enables a continuous manufacturing process where a single resin application performs multiple functions in sequence without requiring intermediate steps or equipment changes. This continuous action approach improves productivity by eliminating the discontinuities associated with switching between different resin compositions and manufacturing setups
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 approach provides excellent insulating and coil fixing properties while reducing manufacturing complexity by using a single resin composition, enhancing productivity and maintaining high performance.
Implementation Method 1
a resin composition containing a base unsaturated-polyester resin and/or a base vinyl-ester resin, a base radical-polymerizable monomer, a radical-polymerizable monomer having adhesiveness to the insulating film of the insulation coated conductor, and a photo-radical polymerization initiator
Data Source
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AI summary
A resin composition (601) containing the following is prepared: a base unsaturated-polyester resin and/or a base vinyl-ester resin; a base radical-polymerizable monomer; a radical-polymerizable monomer having a thermally latent isocyanate group; a photo-radical polymerization initiator; and an alkylborane and/or an alkoxyamine derivative. A stator coil (60) in a stator (20) in a dynamo-electric machine (10) is coated using said resin composition (601) only, i.e. just the one resin composition. An insulated coated section (29A) and a conductor-exposing section (29B) of a join-side coil end (62) are also coated using said resin composition (601).