Integral Stator Core Resin Molding Insulation
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Solution Overview
Problem
The assembly process of conventional stators is complex and costly due to the need for precise placement and securing of slot cells between teeth before winding the coil, which complicates the manufacturing process.
Innovation Solution
An integrated stator core with an annular back yoke and teeth, where an insulator is molded with the stator core through resin molding to cover the slot portions, eliminating the need for slot cells and simplifying the assembly process by providing insulation between the teeth and the coil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If slot cells are used to insulate coils from teeth, then insulation is provided, but the assembly process becomes complicated and costly
Solution Approach 1:
The insulator is merged with the stator core to form an integrated structure. The insulator is molded integrally with the stator core through resin molding, combining two previously separate components (insulator and stator core) into one unified structure, thereby eliminating the need for separate slot cells and simplifying the assembly process
Solution Approach 2:
The integrated insulator serves multiple functions simultaneously: it provides electrical insulation between the coil and teeth, acts as a structural component of the stator core, and eliminates the need for separate insulation components. This multi-functional design reduces the number of parts and simplifies assembly
2Reliability
If slot cells are placed and secured in each slot portion, then insulation is ensured, but manufacturing cost increases
Solution Approach 1:
The insulator and stator core are merged into a single integrated component through resin molding. This eliminates the need for separate slot cells and their associated placement and securing operations, reducing manufacturing steps and labor costs while ensuring reliable insulation
Solution Approach 2:
The insulator is pre-formed as an integral part of the stator core during the molding process, before coil assembly. This preliminary integration of the insulator into the stator core structure eliminates subsequent steps of placing and securing separate insulation components, reducing manufacturing complexity and cost
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 configuration allows for a simpler and cost-effective assembly process by integrating the insulator with the stator core, ensuring effective insulation without reducing the winding area and enhancing the structural integrity and performance of the motor.
Implementation Method 1
the insulator is molded integrally with the stator core through resin molding in such a way that the insulator covers an inner surface of a slot portion of the stator core
Data Source
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AI summary
A stator (5) includes a stator core (510) in which an annular back yoke (511) is integrated with a plurality of teeth (512) circumferentially arranged on the back yoke (511) at intervals, and an insulator (530, 1530) that sandwiches the stator core (510) from both axial sides of the stator core (510). The insulator (530, 1530) is molded integrally with the stator core (510) through resin molding in such a way that the insulator (530) covers an inner surface of a slot portion (514) of the stator core (510). Thereby a stator that can be assembled by a simpler process is provided.