Stator Busbar Resin Layout for Better Heat Dissipation
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Solution Overview
Problem
Conventional stator designs with busbars integrated into insulating resin suffer from poor heat dissipation due to the low thermal conductivity of the resin, leading to increased heat generation, reduced motor performance, and issues like insufficient torque.
Innovation Solution
A stator design that includes a busbar with an extending portion partially exposed through the insulating resin, sealed by a resin with higher thermal conductivity, allowing for improved heat dissipation without compromising moldability or increasing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If busbars are integrated with insulating resin, then ease of assembly is improved, but heat dissipation deteriorates
Solution Approach 1:
The patent applies local quality by differentiating the resin material properties in different regions: the insulating resin covers most of the busbar for electrical insulation, while the sealing resin with higher thermal conductivity is applied specifically to the exposed portion of the extending portion where heat dissipation is needed. This localized material differentiation resolves the contradiction by providing both insulation and heat dissipation in appropriate locations.
Solution Approach 2:
The patent uses composite materials by combining two types of resin: insulating resin for electrical isolation and sealing resin with higher thermal conductivity for heat dissipation. The sealing resin is molded to seal the exposed portion of the busbar's extending portion, creating a composite structure that simultaneously achieves ease of assembly (through integral molding) and improved heat dissipation (through thermally conductive sealing resin).
2Temperature
If filler material is added to raise thermal conductivity, then heat dissipation is improved, but moldability and cost deteriorate
Solution Approach 1:
The patent extracts the heat dissipation function from the insulating resin by using a separate sealing resin material with higher thermal conductivity. Instead of modifying the insulating resin with fillers (which would affect moldability), the solution separates the insulation function (performed by insulating resin) from the heat dissipation function (performed by sealing resin), thereby achieving improved thermal conductivity without compromising moldability.
3Reliability
If busbars are covered with insulating resin, then electrical insulation is improved, but heat dissipation deteriorates
Solution Approach 1:
The patent applies local quality by differentiating the resin material properties in different regions: the insulating resin covers most of the busbar for electrical insulation, while the sealing resin with higher thermal conductivity is applied specifically to the exposed portion of the extending portion where heat dissipation is needed. This localized material differentiation resolves the contradiction by providing both insulation and heat dissipation in appropriate locations.
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
The proposed stator design enhances heat dissipation of the busbar, leading to improved motor performance and reduced issues like insufficient torque, while maintaining cost-effectiveness and moldability.
Implementation Method 1
a sealing resin formed of a resin with higher thermal conductivity than the insulating resin, the sealing resin sealing in at least an exposed portion of the extending portion that is exposed through the insulating resin. Heat of the busbar may be dissipated through the sealing resin.
Data Source
AI summary
End portions of coils that are wound round teeth of a stator core of a stator are joined to joining portions of busbars that are disposed adjacent to the stator core. The busbars include extending portions that extend in the circumferential direction of the stator core. An insulating resin is molded integrally with the busbars. The extending portions are partially exposed through the insulating resin. These exposed portions of the extending portions are sealed in by a sealing resin that is formed of a resin with higher thermal conductivity than the insulating resin.