Stator Busbar Module Structure for Stronger Coil-End Adhesive Fixing
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Solution Overview
Problem
Conventional stators face challenges in securely fixing the busbar module to the coil end portion due to limited adhesive contact area, leading to insufficient adhesive strength and potential vibration-induced durability issues in electrical connections.
Innovation Solution
The stator design incorporates a busbar module with a module body featuring holes that penetrate the module body and bridge portions extending from the inner peripheral surface, allowing adhesive to fill and cure within these holes, thereby increasing the contact area between the adhesive and the module body, enhancing the fixing strength of the busbar module to the coil end portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If through grooves and bridges are formed on the peripheral edge of the module body, then the busbar module can be fixed to the coil end portion, but it is not easy to apply adhesive to completely surround the bridges and sufficient adhesive strength cannot be secured due to lack of contact area
Solution Approach 1:
The invention transitions from a two-dimensional surface adhesive application (on the peripheral edge) to a three-dimensional volume adhesive application (inside the hole). By forming a hole that penetrates the module body and introducing adhesive into this hole, the adhesive can surround the bridge portion completely in three dimensions, ensuring sufficient contact area and adhesive strength while eliminating the difficulty of applying adhesive around peripheral bridges.
2Strength
If the busbar module is fixed with bolts, then the fixing strength is sufficient, but a space for arranging bolts and fixing portion is required making the stator larger
Solution Approach 1:
The invention merges the functions of mechanical support (bridge portion) and adhesive bonding (hole filled with adhesive) into a single integrated structure. The bridge portion provides structural support while the hole filled with adhesive provides bonding, eliminating the need for separate bolt fixing structures and reducing overall stator size while maintaining sufficient fixing strength.
Solution Approach 2:
The invention replaces the mechanical bolt-fixing system with a chemical adhesive bonding system. Instead of using bolts that require holes through the coil end portion and module body, the invention uses adhesive introduced into the hole that cures to bond the bridge portion to the coil end portion, achieving equivalent or superior fixing strength with reduced space requirements.
3Reliability
If adhesive is applied around the bridge on the peripheral edge, then the busbar module can be fixed, but the contact area between adhesive and module body is insufficient leading to reduced adhesive strength
Solution Approach 1:
The invention increases the adhesive contact area by moving from surface-level application to three-dimensional volume filling. The adhesive is introduced into the hole and surrounds the bridge portion completely, creating contact areas on all surfaces of the bridge portion (top, bottom, and sides) rather than only on the peripheral edge, thereby significantly increasing the total contact area and adhesive strength.
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 design significantly improves the adhesive strength between the busbar module and the coil end portion, ensuring stable electrical connections and reduced vibration-induced stress on welded portions, thus enhancing the durability of the stator.
Implementation Method 1
a bridge portion that extends from a part of the inner peripheral surface of the hole to another part of the inner peripheral surface so as to divide an inside of the hole into a plurality of opening regions and is fixed to the coil end portion with an adhesive introduced into the hole and cured therein
Data Source
AI summary
A stator of the present disclosure includes a stator core, a stator coil wound around the stator core, and a busbar module electrically connected to the stator coil and fixed to a coil end portion formed on one end side of the stator core. The busbar module includes a module body that holds a conductive member, a hole that penetrates the module body, and a bridge portion that extends from a part of the inner peripheral surface of the hole to another part of the inner peripheral surface so as to divide an inside of the hole into a plurality of opening regions and is fixed to the coil end portion with an adhesive introduced into the hole and cured therein. In the stator, the busbar module is fixed more firmly to the coil end formed on one end side of the stator core with the adhesive.