Stator Coil Module Resin Insulation for Higher Slot Space Factor
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Solution Overview
Problem
The existing method for manufacturing stators results in a reduction of the space factor in slot accommodated parts due to the excessive thickness of insulating coating films, which is not necessary for parts of the same phase, leading to inefficiencies in insulation and space utilization.
Innovation Solution
A method involving the formation of a coil module with insulating resin, where the resin member is molded to appropriate thicknesses between and around slot accommodated parts, allowing for efficient insulation without excessive coating, and the module is inserted into the stator core slots, eliminating the need for additional insulating members and fixing jigs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thick insulating coating film is formed on slot accommodated parts to secure insulation between different phases, then insulation property is improved, but space factor of slot accommodated parts in slot becomes smaller
Solution Approach 1:
The patent applies local quality by forming insulating coating films with different thicknesses at different locations. Specifically, a first insulating coating film with a first thickness is formed on slot accommodated parts that are in contact with other slot accommodated parts, while a second insulating coating film with a second thickness (smaller than the first) is formed on slot accommodated parts that are not in contact with other slot accommodated parts. This localized differentiation ensures adequate insulation where needed while preserving space factor where insulation is not required.
2Reliability
If a uniform thick insulating coating film is formed on all slot accommodated parts, then insulation between different phases is secured, but insulation between same phases becomes excessive and space is wasted
Solution Approach 1:
The patent implements local quality by differentiating the insulating coating film thickness based on the spatial relationship between slot accommodated parts. The first insulating coating film is formed on parts requiring insulation from different phases, while the second insulating coating film with reduced thickness is formed on parts adjacent to same-phase parts. This approach eliminates excessive insulation material while maintaining manufacturing simplicity through a systematic coating process.
3Reliability
If insulating coating film thickness is increased to ensure insulation, then insulation property is improved, but the space available for slot accommodated parts in the slot is reduced
Solution Approach 1:
The patent applies local quality by forming insulating coating films with different thicknesses at different locations. Specifically, a first insulating coating film with a first thickness is formed on slot accommodated parts that are in contact with other slot accommodated parts, while a second insulating coating film with a second thickness (smaller than the first) is formed on slot accommodated parts that are not in contact with other slot accommodated parts. This localized differentiation ensures adequate insulation where needed while preserving space factor where insulation is not required.
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 prevents the reduction of the space factor in slot accommodated parts, ensures appropriate insulation, and simplifies the manufacturing process by omitting the need for separate insulating members and fixing jigs, thereby enhancing the efficiency and design of the stator.
Implementation Method 1
a module forming step of forming a coil module in which a plurality of slot accommodated parts are integrally molded with an insulating resin member by filling a space between the plurality of slot accommodated parts with the resin member and covering a periphery of the plurality of slot accommodated parts with the resin member
Data Source
AI summary
The method for manufacturing a stator includes: a module forming step of forming a coil module in which a plurality of slot accommodated parts are integrally molded with an insulating resin member by filling a space between the plurality of slot accommodated parts and covering a periphery of the plurality of slot accommodated parts with the resin member in a state where the plurality of slot accommodated parts that are to be disposed in a slot of a stator core are arranged such that the plurality of slot accommodated parts are allowed to be disposed in the slots.