Split-Core Stator Terminal Holder Insulation for Leakage Control
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Solution Overview
Problem
In existing vehicle driving motors, the insulation effect between terminal holders is reduced due to gaps generated when multiple bobbins are circumferentially arranged, leading to increased current leakage and higher manufacturing costs.
Innovation Solution
A stator and split-core assembly design that includes an individual terminal holder for each split core, featuring an insulating protrusion and groove configuration to effectively shield the split core from conductive plates and prevent current leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple bobbins are circumferentially arranged to form a stator, then the manufacturing process is simplified and material cost is reduced, but gaps are generated between terminal holders causing decreased insulation effect and increased current leakage
Solution Approach 1:
An insulating protrusion is introduced as an intermediary element between adjacent terminal holders to bridge the gap and restore insulation. The protrusion extends from one terminal holder into the gap space, making contact with or approaching the adjacent terminal holder, thereby mediating the insulation function across the gap without requiring changes to the overall modular structure
Solution Approach 2:
The insulation solution moves from a two-dimensional surface approach to a three-dimensional volumetric approach by adding protrusions that extend into the gap space. This dimensional change allows the insulating material to occupy the previously problematic gap volume, effectively blocking current leakage paths in three-dimensional space
2Ease of manufacture
If multiple bobbins are circumferentially arranged to form a stator, then manufacturing cost is reduced, but gaps between terminal holders increase the possibility of current leakage
Solution Approach 1:
The insulating protrusion acts as a mediator that blocks the harmful current leakage path between conductive terminal holders. By positioning the protrusion in the gap region, it creates an insulating barrier that prevents direct electrical contact, thereby eliminating the harmful effect while preserving the cost-effective modular architecture
Solution Approach 2:
The gap that originally caused harm (current leakage) is converted into a beneficial feature by filling it with insulating material. The protrusion transforms the harmful empty space into a useful insulating region, turning the structural weakness into a strength that actively prevents current leakage
Data Source
AI summary
A stator includes a split-core assembly that includes a split core, a bobbin, a coil, and a terminal holder. The terminal holder has an insulating protrusion, and when two split-core assemblies are coupled to each other, the insulating protrusion of any one terminal holder overlaps the other terminal holder.