Electric Machine Stator Plug-In Winding for CNT Coil Joining
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Solution Overview
Problem
Existing methods for connecting carbon nanotube (CNT) conductor elements in electrical machines are not technically feasible due to inadequate temperature resistance and strength, making conventional joining methods like welding or soldering impractical.
Innovation Solution
The use of plug-in conductor elements made from carbon nanotubes and/or graphene fibers, combined with electrically non-conductive conductor joining devices and electrically conductive joining agents, allows for reliable mechanical and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional joining methods (welding or soldering) are used to connect CNT conductor elements, then strong electrical connection is achieved, but the joint fails to meet temperature resistance and strength requirements
Solution Approach 1:
The patent introduces an electrically conductive joining agent as an intermediary substance between the CNT conductor elements and the interconnection ring. This joining agent provides both mechanical adhesion and electrical conductivity, serving as a mediator that satisfies multiple requirements simultaneously. The joining agent is applied in the recess of the conductor joining device to create a reliable joint that meets both temperature resistance and electrical connection requirements.
Solution Approach 2:
The patent employs composite material structures: the conductor elements are made of carbon nanotubes (a composite material at the nanoscale), and the joining system combines an electrically non-conductive joining device with an electrically conductive joining agent. This composite approach allows the system to leverage the high temperature resistance of the non-conductive joining device while the conductive joining agent provides the necessary electrical connection.
2Reliability
If conventional joining methods are used to connect CNT conductor elements, then electrical connection is achieved, but the joint strength is insufficient
Solution Approach 1:
The conductor joining device features a recess with a specific curved geometry that receives the conductor element ends. This recess structure provides mechanical constraint and distribution of stress, enhancing the joint strength. The insertion slots also have specific geometric designs that facilitate proper positioning and mechanical interlocking of the conductor elements.
Solution Approach 2:
The electrically conductive joining agent acts as a mediator that provides both mechanical bonding strength and electrical conductivity. This joining agent is specifically designed to create strong adhesive bonds between the CNT conductor elements and the interconnection ring, while simultaneously maintaining electrical continuity.
3Reliability
If CNT conductor elements are used in electrical windings, then advanced electrical properties are achieved, but conventional joining methods become technically infeasible
Solution Approach 1:
The electrically conductive joining agent serves as a mediator that enables the joining of CNT conductor elements without requiring conventional high-temperature welding or soldering processes. This joining agent can be applied using simpler manufacturing methods such as dispensing or dipping, making the manufacturing process feasible while maintaining high electrical winding performance.
Solution Approach 2:
The patent changes the joining parameters from high-temperature processes (welding/soldering) to lower-temperature processes using the conductive joining agent. This parameter change makes the joining process compatible with CNT conductor elements, which may be sensitive to high temperatures, while still achieving reliable electrical and mechanical connections.
4Reliability
If conductor joining devices are made electrically non-conductive, then insulation from busbars is ensured, but electrical connection of conductor elements must be achieved through conductive joining means
Solution Approach 1:
The conductor joining device is segmented into distinct functional zones: the main body (electrically non-conductive) that provides insulation and structural support, the recess that houses the joining interface, and the insertion slots that guide the conductor elements. This segmentation allows each part to perform its specific function optimally.
Solution Approach 2:
The electrically conductive joining agent acts as an intermediary that bridges the gap between the electrically non-conductive joining device and the conductor elements. This allows the joining device to maintain its insulating properties while still enabling electrical connection through the conductive joining agent applied in the recess.
Data Source
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AI summary
A stator of an electric machine is already known, comprising stator teeth and grooves formed between the stator teeth, in which electrical conductor elements of an electrical individual coil winding are provided as individual coils, wherein an interconnection ring is provided on at least one end side of the stator, which has a ring section and multiple, in particular a number corresponding to the number of stator teeth, tooth sections protruding from the ring section in the radial direction. The interconnection ring comprises multiple bus bars for interconnecting the electrical individual coils of the electrical winding. The individual coils are produced from a conventional conductor material, e.g. copper. In the stator according to the invention, an electrical winding made of CNT conductor elements is provided. According to the invention: the conductor elements (4) of the electrical winding are configured as insertable conductor elements (4) of the electrical winding designed as a plug-in winding; the conductor elements (4) are each formed of a combination of carbon nanotubes and/or graphene fibres; and at least one electrically non-conductive conductor joining device (12) is provided on at least one of the tooth sections (10) of the interconnection ring (5), to which two respective conductor ends of two different conductor elements (4) are electrically connected by means of an electrically conductive joining means.