Segmented Stator Insulator Structure for Accurate Molding Assembly
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Solution Overview
Problem
Conventional insulators for electric motors have complex shapes due to integrated coil lead-out portions, leading to reduced molding accuracy and increased deformation, which in turn affect assemblability.
Innovation Solution
The insulator is designed with a first insulator having a coil lead-out portion only on one core end surface covering portion and a second insulator with a longer skirt portion in the axial direction, improving the structural integrity and simplifying the molding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the insulator is integrally molded with a coil lead-out portion, then the insulator can provide insulation and lead out coils simultaneously, but the insulator shape becomes complicated and molding accuracy deteriorates
Solution Approach 1:
The insulator is divided into two separate components: a first insulator with the coil lead-out portion and a second insulator without it. This segmentation allows each component to have a simpler shape suitable for accurate molding, while together they provide the complete functionality of insulation and coil lead-out. The first insulator includes the coil lead-out portion for leading out terminal portions of coils, while the second insulator compensates with a longer skirt portion to maintain overall coverage.
2Adaptability or versatility
If the insulator is integrally molded with a coil lead-out portion, then the insulator can provide insulation and lead out coils simultaneously, but deformation after molding becomes large
Solution Approach 1:
By separating the insulator into two pieces, each with simpler geometry, the molding process produces less deformation. The first insulator handles the coil lead-out function while the second insulator provides structural support with its extended skirt portion, together achieving the required dimensional stability and functional integration.
3Adaptability or versatility
If the insulator is integrally molded with a coil lead-out portion, then the insulator can provide insulation and lead out coils simultaneously, but assemblability deteriorates
Solution Approach 1:
The divided insulator structure with two separate pieces improves assemblability by allowing easier positioning and attachment to the stator core. The first insulator with the coil lead-out portion and the second insulator with the longer skirt portion can be assembled in a modular fashion, facilitating manufacturing and assembly processes while maintaining complete insulation coverage and coil lead-out functionality.
Data Source
AI summary
An insulator, a stator, and an electric motor capable of improving molding accuracy and assemblability are provided. An insulator 26 includes a first insulator 61 and a second insulator 62 to be attached from both axial sides of a stator core. The first insulator 61 has a first core end surface covering portion 65 and a first skirt portion 79. The second insulator 62 has a second core end surface covering portion 265 and a second skirt portion 279. The insulator 26 includes a coil lead-out portion 77 provided integrally with only the first core end surface covering portion 65 for leading out terminal portions of coils from the first insulator 61 to the outside. A length of the longest portion of the second skirt portion 279 in the axial direction is greater than a length of the longest portion of the first skirt portion 79 in the axial direction.