Split Stator Insulation Structure for Dust-Resistant Coil Connections

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Solution Overview

Problem

Conventional stators face insulation reduction issues due to dust accumulation at the split location in the splittable insulating member, which affects the conductive members.

Innovation Solution

The insulating member is configured to be splittable with an auxiliary insulating means provided at the split location, such as protrusions and recesses or insulating coatings, to maintain insulation despite dust accumulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the insulating member is made splittable to facilitate assembly, then ease of manufacture is improved, but insulation reliability deteriorates due to dust accumulation at the split location

Engineering Contradiction:

Improveease of assemblyVSAvoidinsulation reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

A dust prevention member (auxiliary insulating means) is introduced as an intermediary component between the two halves of the splittable insulating member. This dust prevention member fills the gap at the split location, preventing dust from entering while maintaining the insulating function. The dust prevention member acts as a mediator that resolves the conflict between the need for a splittable structure (for ease of assembly) and the need to maintain insulation reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the insulating member is made splittable into two halves, then ease of operation during assembly is improved, but harmful factors increase due to dust accumulation in the gap

Engineering Contradiction:

Improveease of assemblyVSAvoiddust accumulation

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The dust prevention member serves as an intermediary element that fills the gap created by the splittable insulating member structure. It prevents dust from accumulating in the gap while allowing the insulating member to remain splittable for ease of assembly. The dust prevention member effectively mediates between the operational advantage of splittability and the harmful effect of dust accumulation.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the gap at the split location is reduced to prevent dust accumulation, then reliability is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveinsulation reliabilityVSAvoidgap control precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

Instead of relying on precise manufacturing to minimize the gap at the split location, a dust prevention member is introduced as an auxiliary insulating means. This member fills the gap and prevents dust accumulation, thereby maintaining insulation reliability without imposing stringent manufacturing precision requirements. The dust prevention member acts as a compensatory element that eliminates the need for tight gap control.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS20260018951A1Stator, Motor and Motor Actuator Using Stator

Publication Date: 2026.01.15 TOKYO PARTS IND CO LTD

AI summary

A stator has a core, an insulating member covering the core, windings, wound around the insulating member, and conductive members, which supply drive power to the windings. The conductive members are inserted into insertion holes in the insulating member and are connected to coil ends. The insulating member is configured to be splittable such that a gap is formed at a split location. Auxiliary insulating means are provided at positions corresponding to the gap at at least one of the peripheries of the insertion holes and the conductive members.