Stator Adhesive Layer Positioning for Rotary Electric Machine
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Solution Overview
Problem
In rotary electric machines, the foamed adhesion section used to fix the stator core to the coil can protrude and peel off due to contact with refrigerant flow, leading to internal contamination.
Innovation Solution
The adhesive layer is disposed such that its end portions in the axial direction are positioned further inside than the stator core's end surfaces, preventing protrusion and peeling, and is formed using a foaming adhesive agent applied on the central section of the insulating paper, which is heated to adhere the coil to the stator core without protruding from the slots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a foamed adhesion section is formed on insulating paper to fix the coil to the stator core, then adhesion strength is improved, but the adhesive layer may protrude from slots and peel off due to refrigerant flow contact
Solution Approach 1:
The adhesive layer is positioned specifically at the central section of the insulating paper in the axial direction, creating a localized adhesion zone. This local quality approach ensures strong bonding where needed while preventing protrusion at the ends of the slots, thus resolving the contradiction between adhesion strength and contamination prevention.
Solution Approach 2:
The adhesive layer is pre-positioned within the slot boundaries before the coil is installed and before refrigerant flow contact occurs. This preliminary positioning prevents the adhesive from protruding and being exposed to refrigerant flow, thereby preventing peeling and contamination while maintaining effective adhesion.
2Area of stationary object
If the adhesive layer extends to the end surfaces of the stator core, then adhesion coverage is improved, but protrusion and peeling occur due to contact with refrigerant flow
Solution Approach 1:
Instead of extending the adhesive layer uniformly to the end surfaces, the invention concentrates the adhesive layer at the central section of the insulating paper. This creates a focused adhesion zone with sufficient coverage for bonding while eliminating exposure to harmful refrigerant flow at the end surfaces.
Solution Approach 2:
The invention acknowledges that extending adhesive coverage to end surfaces would cause harm from refrigerant contact, but converts this by strategically positioning the adhesive only where it provides benefit (central section) while avoiding the harmful zone (end surfaces exposed to refrigerant flow).
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
This configuration effectively fixes the stator core to the coil while preventing internal contamination of the rotary electric machine by suppressing contact between the adhesive layer and refrigerant flow, ensuring reliable adhesion and easy formation of the stator.
Implementation Method 1
the foamed adhesion section fixes a coil winding to the stator core by adhesion using expansion and stickiness generated through heating
Implementation Method 2
a foamed adhesion section is formed on a portion of insulating paper corresponding to both end portions of the slots in an axial direction
Implementation Method 3
an adhesive layer and disposed between an inner circumferential surface of the slot and the coil
Data Source
AI summary
Provided is a stator for a rotary electric machine capable of fixing a stator core and a coil while preventing internal contamination of the rotary electric machine. A stator (5) for a rotary electric machine includes a stator core (11) having teeth (21) and slots (23) alternately in a circumferential direction, a coil (13) mounted on the stator core (11), and an insulating layer (35) and a foamed adhesive layer (37) disposed between an inner circumferential surface of the slot (23) and the coil (13). The formed adhesive layer (37) is disposed such that an end portion of at least one side thereof in an axial direction of the stator core (11) is disposed further inside than an end surface (11a) of a side of the stator core (11) in the axial direction.