Resin-Filled Stator Slots for Coil Insulation and Heat Dissipation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing stators with coils fixed via insulating paper suffer from inadequate heat dissipation, which affects the performance and efficiency of the motor.
Innovation Solution
The stator design incorporates insulating resin that completely fills the gaps between the inner wall of the tooth and the covering portion of the winding wire, eliminating the need for insulating paper and enhancing heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating paper is used to fix the coil to the stator core, then insulation is provided, but heat dissipation is insufficient
Solution Approach 1:
The patent changes the material parameter from insulating paper to insulating resin, which has superior thermal conductivity. The insulating resin completely fills the slots and gaps between the tooth inner wall and the covering portion, creating direct thermal contact pathways that significantly improve heat dissipation while maintaining insulation properties.
Solution Approach 2:
The patent uses a composite structure where insulating resin combines both insulation and heat dissipation functions. The resin fills all gaps and voids in the slot, creating a composite material system that integrates electrical insulation with thermal management, eliminating the need for separate insulating paper layers.
2Reliability
If insulating paper is interposed between the tooth and winding wire, then insulation is ensured, but heat dissipation path is blocked
Solution Approach 1:
The patent extracts and eliminates the insulating paper layer from the slot structure. By removing this thermal barrier, the heat dissipation path from the winding wire to the tooth is directly opened. The insulating resin is applied in a way that fills gaps without forming an additional insulating paper-like barrier, thus taking out the harmful element while preserving necessary insulation.
Solution Approach 2:
The insulating resin acts as an improved intermediary material that replaces insulating paper. It provides the necessary electrical insulation between the winding wire and tooth while simultaneously serving as a thermal conductor due to its ability to completely fill gaps and create continuous thermal pathways, thus mediating both electrical and thermal requirements.
3Quantity of substance
If gaps between tooth and covering portion are not completely filled, then material usage is reduced, but heat dissipation and insulation are compromised
Solution Approach 1:
The patent applies insulating resin in an excessive manner by completely filling all gaps and voids in the slot rather than just partially filling them. This ensures that no air pockets or voids remain that could compromise heat dissipation or insulation. The complete filling approach, while using more material, guarantees optimal thermal and electrical performance.
Solution Approach 2:
The patent applies insulating resin with different local qualities: it completely fills the gaps between the tooth inner wall and covering portion to ensure thermal contact and insulation, while the overall slot filling provides structural support. The resin's properties are optimized for the specific local requirement of heat dissipation and insulation at the tooth-wire interface.
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
Improved heat dissipation leads to increased maximum torque, reduced material costs, and enhanced insulation, allowing for a more efficient and cost-effective motor performance.
Implementation Method 1
insulating resin filling the slots... improve heat dissipation of the coil
Data Source
AI summary
A stator includes a stator core and a coil. The stator core includes an annular yoke portion and a plurality of teeth that are annularly aligned. The plurality of teeth protrude from the yoke portion. Slots are constituted respectively by two adjacent teeth of the plurality of teeth. Insulating resin fills the slots of the stator. The coil includes a winding wire passed through the slots and wound around the teeth. The winding wire includes a core wire forming a conductive path and a covering portion covering the core wire. In each of the slots, the insulating resin completely fills a gap between an inner wall of the tooth and the covering portion.