Stator Cover Fixation Using Foamable Slot Insulation
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Solution Overview
Problem
Existing stators of rotary electric machines require complex processes to fix a cover member to the stator core, affecting production efficiency.
Innovation Solution
A stator configuration where a foamable insulation member covers the conductor wire portions and is bonded to a cylindrical cover member, allowing easy fixation without complex machining, and forms a cooling liquid passage for efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If engagement holes are formed on the cover member and lock protrusion portions are formed on the stator core to fix the cover member, then the cover member can be securely fixed to the stator core, but the manufacturing process becomes complicated and production efficiency decreases
Solution Approach 1:
The invention extracts the fixation function from the mechanical engagement structure (holes and protrusions) and transfers it to the foamable insulation member that naturally bonds the cover member to the stator core through slot openings, eliminating the need for complex machining of engagement features
Solution Approach 2:
The foamable insulation member serves as an intermediary substance that provides the fixation function between the cover member and stator core, replacing the direct mechanical engagement structure and enabling simple bonding without complex machining
2Reliability
If engagement holes are formed on the cover member and lock protrusion portions are formed on the stator core to fix the cover member, then the cover member can be securely fixed to the stator core, but production efficiency decreases due to complicated processes
Solution Approach 1:
The invention extracts the fixation function from the mechanical engagement structure (holes and protrusions) and transfers it to the foamable insulation member that naturally bonds the cover member to the stator core through slot openings, eliminating the need for complex machining operations and improving production efficiency
3Length of moving object
If the cover member thickness is reduced to improve cooling efficiency and magnetic performance, then cooling and magnetic performance improve, but the structural strength and fixation reliability may decrease
Solution Approach 1:
The foamable insulation member serves as an intermediary that provides bonding and structural support, enabling the cover member to be made thinner without compromising overall structural strength, as the foam material compensates for the reduced thickness
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
Facilitates easy and reliable fixation of the cover member to the stator core, enhances magnetic performance, and improves cooling efficiency while reducing the cover member's thickness and weight.
Implementation Method 1
a foamable insulation member that covers an outer surface of a plurality of conductor wire portions of the coil and is bonded to the outer circumferential surface of the cover member through the opening is loaded in each of the slots
Data Source
AI summary
A stator includes: a stator core having an annular shape, a coil, and a cover member having a cylindrical shape. The stator core includes a plurality of teeth portions that are aligned in a circumferential direction and a plurality of slots that are formed between the teeth portions which are adjacent to each other in the circumferential direction. In the coil, a plurality of conductor wire portions are wound around each of the teeth portions through the slots. The cover member is arranged to be inserted into an inner circumferential portion of the stator core such that an outer circumferential surface faces an opening on an inside in a radial direction of the plurality of slots. A foamable insulation member that covers an outer surface of the plurality of the conductor wire portions of the coil and is bonded to the outer circumferential surface of the cover member through the opening of the slots is loaded in each of the slots.