Stator Busbar Overmolding for Wet-Environment Insulation
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Solution Overview
Problem
Existing methods for manufacturing stator-assemblies for electric machines in damp and wet environments lack efficient electrical insulation and result in increased manufacturing time and costs due to complex handling and material usage.
Innovation Solution
The method involves overmolding the busbar with electrically insulating material before mounting it on the stator, followed by connecting the coils and overmolding the connection points with additional insulating material, simplifying the process and improving insulation precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the busbar is overmolded with electrically insulating material before mounting on the stator, then the electrical insulation precision is improved and handling is simplified, but the manufacturing process requires additional steps
Solution Approach 1:
The busbar is overmolded with electrically insulating material in advance, before being mounted on the stator. This preliminary action ensures precise electrical insulation is achieved during a dedicated overmolding step, allowing the busbar to be fully insulated before handling and connection operations, thereby improving insulation precision while organizing the complexity into sequential steps.
2Ease of operation
If the busbar is overmolded before mounting on the stator, then the handling during manufacture is simplified, but the manufacturing time increases due to additional processing steps
Solution Approach 1:
The busbar is overmolded with insulating material before mounting, which simplifies subsequent handling operations. The pre-insulated busbar can be directly positioned and connected without requiring additional insulation operations during assembly, improving ease of operation despite the added preliminary step.
Solution Approach 2:
The overmolding of the busbar is integrated into the manufacturing flow as a preliminary step that combines insulation application with busbar preparation. This merging of functions allows the insulating material to be applied in a dedicated process step while the busbar is still in a convenient state for overmolding, optimizing the balance between handling ease and manufacturing time.
3Reliability
If the connection points between busbar and stator are overmolded with electrically insulating material, then the electrical insulation is improved, but the consumption of electrically insulating material increases
Solution Approach 1:
The busbar is overmolded with electrically insulating material before mounting on the stator, which ensures that the bulk of the insulation is applied in advance. This preliminary overmolding covers the entire busbar surface, reducing the need for additional insulating material during subsequent connection operations, while still ensuring reliable insulation at connection points.
Solution Approach 2:
The connection points between the busbar and stator are selectively overmolded with electrically insulating material. This localized application ensures that insulation is precisely applied only where electrical insulation is critical, rather than covering the entire assembly, thereby improving insulation reliability at key locations while minimizing material consumption.
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 approach reduces manufacturing time and costs while enhancing electrical insulation, making it suitable for use in wet environments, such as electric compressors in air-conditioning systems.
Implementation Method 1
the busbar is first overmolded with an electrically insulating material
Implementation Method 2
the connection points between the busbar and the stator are overmolded with an electrically insulating material
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to a method for manufacturing a stator-assembly (1) for an electric machine (100), which comprises a stator (2) and a busbar (4) for electrically connecting coils (6) of the stator (2) to a controller (101) of the electric machine (100). Simplified and cost-effective manufacture with reduced cycle times is achieved by encasing the busbar (4) with an electrically insulating busbar material and then electrically connecting it to the coils (4), with joint sections (8) in which the coils (4) are electrically connected to the busbar (4) also being separately electrically insulated after said electrical connecting. The invention also relates to a stator-assembly (1) manufactured in this way and to an electric machine (100) having such a stator-assembly (1).