Stacked High-Voltage Terminal Layout for Compact Stator Integration
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Solution Overview
Problem
Existing high-voltage terminals for stators in electric machines are not optimized for compact integration and secure attachment, with a high risk of contact pins breaking with conductors.
Innovation Solution
A high-voltage terminal design featuring stacked conductor phases and a star phase formed from parallel rail tracks, isolated by spacer elements, embedded in a plastics element, with controlled air gaps and creepage distances, and contact pins secured via embossing and overmolding for robust connection to the stator winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional high-voltage terminal designs are used, then the structure is simple, but the integration into limited stator winding space is not compact
Solution Approach 1:
The patent transitions from planar conductor arrangements to a three-dimensional stacked configuration with conductor phases arranged vertically. Multiple conductor phases are stacked one on top of another, utilizing the third dimension (height/depth) to reduce the footprint area while maintaining electrical functionality. This dimensional transition enables compact integration into limited stator winding spaces.
Solution Approach 2:
The patent implements nested arrangements where conductor phases and insulation layers are stacked concentrically. Each conductor phase is surrounded by insulation, and multiple phases are nested within the same radial space at different axial positions. This nesting approach maximizes space utilization and achieves compact integration.
2Reliability
If conventional attachment mechanisms are used, then the structure is simple, but the risk of contact pin breakage is high
Solution Approach 1:
The patent merges the attachment function with the terminal structure itself. The contact pins are integrated into the conductor phases, and the entire assembly is embedded in a single insulating component that provides both electrical isolation and mechanical support. This integration eliminates separate attachment mechanisms while enhancing reliability through distributed load bearing across multiple embedded contact pins.
Solution Approach 2:
The patent employs redundant contact pin arrangements where multiple contact pins are provided per conductor phase. This redundancy acts as a cushioning mechanism - if one contact pin fails or experiences excessive stress, the other pins continue to carry the load, preventing catastrophic failure and maintaining electrical connection reliability.
3Reliability
If air gaps and creepage distances are maintained with conventional methods, then electrical isolation is achieved, but the space requirement increases
Solution Approach 1:
The patent uses composite insulating materials with high dielectric strength to achieve the required creepage distances and air gaps in minimized space. The insulating component combines multiple materials or layers with different properties - some providing electrical isolation, others providing mechanical support and spacing. This composite approach allows compact design while maintaining reliable electrical isolation.
Solution Approach 2:
The patent applies different insulation thicknesses and material properties at different locations based on local electrical stress requirements. Areas with higher voltage stress receive enhanced insulation, while low-stress areas use minimal insulation. This localized approach optimizes the balance between electrical isolation reliability and space occupation, avoiding uniform over-insulation throughout the structure.
Data Source
AI summary
A high-voltage terminal for a stator, including at least three conductor phases for electrically connecting the high-voltage terminal to a power electronics unit and at least one star phase in the form of a rail, wherein each of the at least three conductor phases is formed of at least two parallel rail sections which are connected so as to be electrically isolated from one another and mutually radially spaced apart via at least one spacer element, preferably via at least two spacer elements, and wherein the at least three conductor phases and the at least one star phase are stacked one on top of the other within the high-voltage terminal to form a rail stack, and are inserted and/or embedded in a plastics element so as to be electrically isolated from one another via the spacer elements.