Stator Corner Protection Member for Insulation and Heat
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing stator designs in electric motors face issues with insulating performance and electrical strength degradation due to wire winding, leading to reduced efficiency and heat radiation, as well as increased costs and time in manufacturing and limited winding space.
Innovation Solution
A stator with a U-shaped protecting member made of insulating material, attached to the tooth parts, which covers only the corners and has a length shorter than half the tooth part's length, preventing wire contact with corners and allowing for a thinner resin coat, thus improving insulation and heat radiation while reducing manufacturing time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resinous insulating member is molded in conformity with the shapes of the tooth part and the slot and inserted into the slot to cover the electric wire winding portion, then insulating performance is improved, but manufacturing time increases and cost increases
Solution Approach 1:
The patent extracts the insulating function from a complex molded resinous member and implements it through a simple protective member attached only to the tooth part corner. This selective extraction of the essential protective function eliminates the need for complex molding and insertion processes, thereby reducing manufacturing time while maintaining insulating performance.
Solution Approach 2:
The patent segments the insulating protection to only the critical corner portion of the tooth part where wire pressing occurs, rather than providing full-slot coverage. This segmentation reduces the size and complexity of the protective member, making it easier and faster to manufacture and attach.
2Reliability
If a resinous insulating member is provided in the slot to cover the electric wire winding portion, then insulating performance is improved, but winding efficiency is reduced due to limited winding space
Solution Approach 1:
The patent applies local quality by providing insulation only at the specific location (tooth part corner) where insulation is most critical, rather than uniformly across the entire slot. This localized approach maintains insulating performance where needed while preserving maximum winding space in the slot, thereby improving winding efficiency.
3Reliability
If a resinous insulating member is provided in the slot to cover the electric wire winding portion, then insulating performance is improved, but heat radiation performance is degraded
Solution Approach 1:
The patent applies local quality by providing insulation only at the tooth part corner where electrical insulation is critical, rather than covering the entire slot. This minimal insulation approach maintains electrical insulation performance while preserving heat radiation pathways in the slot, thereby improving heat radiation performance.
4Reliability
If the thickness of the insulating coat on the stator is increased to prevent wire pressing degradation, then insulating performance is improved, but the slot size is reduced and winding efficiency is reduced
Solution Approach 1:
The patent extracts the insulation function from the stator body itself and provides it through a separate protective member attached only to the corner. This separation allows the main stator insulating coat to remain thin, preserving slot space for winding, while the corner protective member provides targeted insulation where wire pressing occurs.
Solution Approach 2:
The protective member acts as an intermediary between the wire and the stator corner, providing insulation at the critical contact point without requiring a thick insulating coat on the entire stator. This intermediary approach maintains insulation performance while preserving winding space.
Data Source
AI summary
There is provided a stator that can suppress degradation in insulating performance and electrical strength performance, shorten a work time, and improve winding efficiency and heat radiation. The stator 1 includes a yoke part 20 formed to be annular, a plurality of tooth parts 30 protruding from the yoke part 20 in an inward direction perpendicular to an axial direction O of a rotor when the rotor is arranged in the yoke part 20, and protecting members 40 each of which is attached to both end surfaces of the tooth part 30 in the axial direction O to protect a corner of the tooth part 30. The protecting members 40 have a length in a slot 38 between the tooth parts 30 shorter than a half of an entire length of the tooth part 30 in the axial direction.