Stator Insulation Sheet with Dual Adhesives for Wire Insertion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The use of foamed resin in insulation sheets for stators results in high resistance and reduced workability when inserting winding wires, and increasing clearance to mitigate this issue restricts the design of the magnetic circuit and lowers heat conductivity.
Innovation Solution
A stator design featuring an insulation sheet with a foaming adhesive on one surface and a non-foaming adhesive on the other, allowing for easy insertion of winding wires and maintaining close contact post-assembly to preserve heat conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foamed resin is used in the insulation sheet, then the stator and winding wire can be brought into close contact, but the resistance when inserting the winding wire increases and workability is reduced
Solution Approach 1:
The insulation sheet has different adhesive properties on different surfaces: the slot-facing surface uses foaming adhesive for high contact quality, while the winding wire-facing surface uses non-foaming adhesive with lower viscosity for easy insertion. This local differentiation resolves the contradiction between contact quality and insertion workability.
Solution Approach 2:
The adhesive layer is segmented into two distinct types (foaming and non-foaming) applied to different surfaces of the insulation sheet. This segmentation allows each surface to have optimized properties for its specific function, eliminating the need to choose between contact quality and insertion ease.
2Ease of operation
If clearance between the slot and winding wire is increased to reduce insertion resistance, then insertion workability improves, but heat conductivity between the coil and stator is lowered
Solution Approach 1:
The adhesive properties are locally optimized: non-foaming adhesive with lower viscosity is applied only on the winding wire-facing surface to facilitate easy insertion, while the slot-facing surface uses foaming adhesive to ensure close contact and maintain heat conductivity after assembly.
3Reliability
If foaming adhesive is used on both surfaces of the insulation sheet, then close contact is achieved, but the viscosity during insertion causes high resistance and reduced workability
Solution Approach 1:
Different adhesive types are applied to different surfaces based on their functional requirements. The winding wire-facing surface uses non-foaming adhesive for easy assembly, while the slot-facing surface uses foaming adhesive for reliable contact, eliminating the drawbacks of using foaming adhesive on both surfaces.
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 improves workability during assembly by reducing insertion resistance and maintains high heat conductivity between the winding wire and stator, enhancing motor efficiency.
Implementation Method 1
a foaming adhesive to be thermally cured while foaming by heating is disposed on the first adhesive layer
Implementation Method 2
the foaming adhesive to be thermally cured while foaming by heating
Data Source
AI summary
A stator including, a stator core having a slot, a winding wire to be inserted into the slot; and an insulation sheet interposed between the slot and the winding wire and configured to electrically insulate an inner wall of the slot and the winding wire, wherein the insulation sheet includes an insulation paper, a first adhesive layer disposed on a front surface of the insulation paper facing the inner wall of the slot, and a second adhesive layer disposed on a back surface of the insulation paper facing the winding wire, a foaming adhesive to be thermally cured while foaming by heating is disposed on the first adhesive layer, and a non-foaming adhesive having lower viscosity than that of the foaming adhesive when unheated is disposed on the second adhesive layer.