Three-Phase Stator Connector Encapsulation for Compact Watertight Busbars
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Solution Overview
Problem
Existing automotive electric machines with three-phase stators face challenges in water tightness, complexity of electrical connections, and axial dimension reduction, particularly in the integration of busbars and connectors.
Innovation Solution
A three-phase stator design featuring a cylindrical shape with coaxial busbars, insulating supports, and a novel electrical connector with stiff connection conductor elements and an insulating support element, embedded in a heat-conductive resin encapsulation, ensuring fluid-tight sealing and reduced axial dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If busbars are encased in resin for insulation and heat dissipation, then electrical insulation and thermal management are improved, but water tightness is compromised
Solution Approach 1:
The connector is nested within the resin-encased busbar structure. The busbars are first encased in resin for insulation and heat dissipation, then the connector is integrated into this encapsulated structure, creating a nested arrangement that maintains both electrical insulation and improved water tightness through the unified encapsulation approach
2Ease of operation
If traditional electrical connectors are used with multiple connection elements, then electrical connections are established, but device complexity and axial dimensions increase
Solution Approach 1:
Multiple connection elements are merged into a single integrated connector body. Instead of using separate connection elements that would increase complexity and axial dimensions, the invention combines all connection functions into one unified connector structure that is then encapsulated with the busbars, simplifying the overall assembly while maintaining electrical connectivity
Solution Approach 2:
The connector is designed as a multi-functional component that performs both electrical connection and structural integration functions. It serves as both the electrical interface for connecting stator windings and as a structural element that is encapsulated with the busbars, eliminating the need for separate components and reducing overall complexity
3Ease of operation
If traditional electrical connectors are used, then electrical connections are established, but axial dimensions of the stator increase
Solution Approach 1:
The connector and busbar assembly are merged into a single encapsulated unit. By integrating the connector directly with the busbars and enclosing both in resin, the design eliminates gaps and intermediate structures that would increase axial dimensions, achieving a compact configuration that reduces the overall axial length of the stator
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 solution enhances water tightness, simplifies connection methods, reduces stator dimensions, improves thermal dissipation, and increases mechanical resistance, while maintaining electrical efficiency and stability.
Implementation Method 1
the function of transmitting and, thus, dissipating the heat produced by the busbars
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
An electric machine three-phase stator (1) has a casing (5) and three busbars (13) that carry respective contacts (17), within and at an axial end of this casing (5); the contacts are electrically connected to respective outer terminals (28) ; the stator is provided with an electrical connector (20), which is coupled, in a fluid-tight manner, to the same casing (5) and has three connection conductor elements (25); the outer ends of the three conductor elements define the above-mentioned outer terminals (28), while the inner ends (27) of the three conductor elements are respectively fixed to the contacts (17) by means of a fixing system (19); the busbars (13), the contacts (17), fixing system (19), and the inner ends (27) of the three conductor elements are embedded in an encapsulation material (47).