Stacked Stator Core Resin Filling with Mold Cores
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Solution Overview
Problem
Existing methods for manufacturing stacked stator cores face challenges in ensuring effective insulation between the winding coil and the stator core, particularly in maintaining the shape and integrity of the resin portion during the resin filling process, which can lead to leakage and burrs, affecting the motor's performance and efficiency.
Innovation Solution
The proposed solution involves a resin filling device and method that uses mold core members with inclined surfaces to form a filling space and auxiliary spaces, allowing melted resin to fill while keeping the open end portion of the slot unobstructed, ensuring the resin portion does not protrude beyond the slot opening and maintaining a gap for rotor insulation, thus preventing leakage and burrs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the slot is filled with resin to ensure insulation between the winding coil and stator core, then insulation performance is improved, but resin leakage and burrs occur affecting manufacturing precision
Solution Approach 1:
Mold core members are inserted into slots before resin filling to pre-establish the filling space boundaries. This preliminary action defines the resin containment area and prevents leakage during the subsequent resin injection process, resolving the contradiction between achieving good insulation and maintaining manufacturing precision.
Solution Approach 2:
Mold core members act as intermediary elements between the resin and the slot structure. These members create a controlled interface that guides resin flow and containment, enabling complete slot filling for insulation while preventing unwanted resin protrusion and burr formation.
2Reliability
If the resin portion protrudes beyond the slot opening to ensure insulation coverage, then insulation performance is improved, but the stacked stator core shape is distorted
Solution Approach 1:
The mold core members are pre-positioned with their side surfaces extending to or beyond the slot opening level. This preliminary configuration ensures that when resin is filled, it is contained within the mold core boundaries and cannot protrude beyond the slot opening, thus maintaining both insulation coverage and geometric integrity.
Solution Approach 2:
The mold core members create a negative space template that copies the desired final resin shape. By forming the filling space with mold cores that match the target geometry, the resin naturally takes on the correct shape without protrusion, eliminating the need for additional shaping operations.
3Shape
If the slot opening is obstructed to prevent resin protrusion, then shape integrity is improved, but resin filling becomes difficult
Solution Approach 1:
The slot structure is segmented into two functional zones: the filling space (inside the mold core) where resin is contained, and the open slot opening (outside the mold core) where resin can be easily injected. This segmentation allows the slot opening to remain unobstructed for easy filling while the mold core provides the necessary boundaries to prevent protrusion.
Solution Approach 2:
The mold core members extend in the circumferential direction beyond the slot opening while maintaining the filling space within the slot depth. This dimensional arrangement creates a three-dimensional configuration where the resin filling path remains open and accessible, but the lateral extension of mold cores provides containment without obstructing the filling approach.
Data Source
AI summary
A stator core comprises a stack and a resin portion. The stack comprises an annular yoke portion, a plurality of tooth portions, and a plurality of slots. The resin portion covers an inner wall surface of a slot of the plurality of slots. The resin portion protrudes outward relative to an end surface of the stack in a height direction of the stack. The resin portion is formed on at least a part of an end surface of the tooth portion so as to extend from the inner wall surface of the slot around the end surface of the tooth portion. A resin end portion of the resin portion is disposed on the end surface of the stack and a corner of the resin end portion is formed as an inclined surface including a planar surface or curved surface.