Overbaked Stator Core Coating to Prevent Coil Embedding
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Solution Overview
Problem
In the process of winding a coil around the pole teeth of a stator core in a motor, pressure applied to the coil can cause it to become embedded in the electrodeposition coating film, leading to potential winding defects.
Innovation Solution
A motor design featuring a stator core with a surface covered by an epoxy resin-containing electrodeposition coating film that has been subjected to overbaking, reducing the likelihood of the coil being embedded in the coating film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a standard electrodeposition coating film is used on the stator core, then the manufacturing process is simple and cost-effective, but the coil may be embedded into the coating film during winding
Solution Approach 1:
The patent applies parameter changes by modifying the baking temperature and time parameters of the electrodeposition coating film. Specifically, the coating film is baked at a higher temperature (e.g., 200-250°C) for a longer duration than conventional processes, which transforms the physical and chemical properties of the epoxy resin coating. This parameter modification increases the cross-linking density and hardness of the coating, thereby preventing coil embedding during the winding process while maintaining the overall simplicity of the manufacturing approach
Solution Approach 2:
The patent utilizes composite materials by employing an epoxy resin-based electrodeposition coating that combines multiple functional properties. The coating comprises epoxy resin as the base material with added hardeners and potentially other modifiers that create a composite structure with enhanced mechanical properties. This composite coating structure provides both the adhesion needed for standard electrodeposition processes and the hardness required to prevent coil embedding, resolving the contradiction between manufacturing ease and reliability
2Manufacturing precision
If the coating film hardness is increased to prevent coil embedding, then winding defects are reduced, but the coating process becomes more complex
Solution Approach 1:
The patent applies preliminary action by performing an extended high-temperature baking process on the electrodeposition coating film before the coil winding operation. This preliminary thermal treatment pre-hardens the coating surface, creating a rigid protective layer that resists coil embedding during subsequent winding operations. By completing the hardness enhancement step before winding, the process ensures high winding quality without requiring complex real-time adjustments during the winding process itself
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 overbaked coating film provides increased hardness, minimizing the chance of coil embedding during winding and thereby reducing the occurrence of winding defects.
Implementation Method 1
the coating film is an epoxy resin-containing electrodeposition coating film subjected to overbaking
Implementation Method 2
a surface of a stator core constituting the spindle motor is coated by electrodeposition with an insulating material
Data Source
AI summary
A motor includes a stator core including a stacked body of electromagnetic steel plates, a surface of the stacked body is covered with a coating film, and the coating film is an epoxy resin-containing electrodeposition coating film subjected to overbaking.