Rotor Insulation via Injection-Molded Layer for High-Speed Mass Production
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Solution Overview
Problem
Existing methods for insulating laminated cores of electric machine rotors, such as using aramid paper or plastic end disks, are not suitable for mass production and do not provide sufficient strength, especially for high-speed rotors.
Innovation Solution
A rotor design featuring metallic end disks with a coherent, fully areally injection-molded insulation layer that supports both electrical insulation and structural strength, where the layer is applied directly to the laminated core and end disks, optimizing wire winding support and reducing structural space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aramid paper or sheet-like insulating materials are used to insulate laminated cores, then electrical insulation is provided, but the method is not suitable for mass production and increases manufacturing complexity
Solution Approach 1:
The patent changes the physical state and application method of the insulating material from sheet-like aramid paper to a liquid or paste-like injection-moldable material. This material can be injected into the rotor structure and cured to form a coherent insulating layer, enabling automated mass production while maintaining electrical insulation reliability
Solution Approach 2:
The manual or semi-automatic process of applying aramid paper sheets is replaced by an injection molding process. The insulating material is injected under pressure into the rotor structure and cured, automating the insulation application and making it suitable for mass production
2Reliability
If plastic end disks are used to insulate and support the rotor structure, then insulation is provided, but they do not provide sufficient strength for high-speed rotors
Solution Approach 1:
The patent uses composite materials consisting of metal end disks combined with a coherent insulating layer formed from injection-molded material. The metal provides structural strength for high-speed operation while the injected material provides electrical insulation, creating a composite structure that achieves both requirements simultaneously
Solution Approach 2:
The patent merges the structural support function of metal end disks with the electrical insulation function in a single integrated component. The insulating material is injected directly onto and integrated with the metal end disks, combining both functions into one unified structure rather than using separate components
3Reliability
If traditional insulation methods are used, then electrical insulation is achieved, but structural space requirements increase and manufacturing complexity increases
Solution Approach 1:
The patent uses a thin coherent insulating layer formed by injection molding and curing of the material. This thin film-like layer provides adequate electrical insulation while occupying minimal structural space, unlike thicker traditional insulation layers
Solution Approach 2:
The insulating layer is merged with the metal end disks and laminated core structure during the injection molding process. This integration eliminates the need for separate insulation components and reduces overall structural space requirements
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
The solution enables high-speed rotor operation with optimal insulation and increased strength, reducing structural space and enabling efficient series production while maintaining lightweight construction.
Implementation Method 1
the layer acts in particular as electrical insulation or as an insulation layer and here closes, or spans and/or covers, the contact region or the joining point between the laminated core and the end disk arranged thereon
Implementation Method 2
the layer is advantageously formed to optimally guide and support the wire and/or conductor elements
Data Source
AI summary
A rotor, in particular of an electrical machine, has a base body and at least one metallic end plate which is mounted on the base body. The base body and the at least one end plate have a continuous layer which is injection molded.