Motor Stator End-Plate Insulation for Conductive Coolant Environments
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Solution Overview
Problem
The increasing input voltage of motors in electric vehicles and the conductive nature of coolants and oils at high voltages pose higher requirements for the insulation performance of motor stators, which existing technologies have not adequately addressed.
Innovation Solution
A motor stator design featuring a stator core with insulated end plates and a wiring board that forms a pouring cavity for insulating material, enhancing insulation by solidifying the material around exposed treatment positions, thereby improving the motor's insulation capability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the input voltage of motors is increased to meet electric vehicle performance requirements, then the power and efficiency of the motor are improved, but the insulation performance requirements become more stringent due to the conductive nature of coolants and oils at high voltages
Solution Approach 1:
The patent applies preliminary action by pre-defining insulated treatment positions on the end plates before final assembly, and by designing the wiring board with integrated pouring cavities that are prepared in advance to receive insulating material. This ensures insulation is established before the motor operates in the conductive coolant/oil environment, preventing insulation failures at high voltages
Solution Approach 2:
The patent implements local quality by providing insulated treatment positions only at specific locations on the end plates where electrical insulation is critically needed, rather than insulating the entire structure. The insulating material is poured into specific pouring cavities at these localized positions, creating targeted insulation zones that address the high voltage risk areas while maintaining overall design efficiency
2Reliability
If insulated treatment positions are provided on end plates and insulating material is poured into pouring cavities to enhance insulation, then the insulation performance is improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent merges the wiring board structure with the pouring cavity formation, where the wiring board's casing portions directly create the pouring cavities when mounted on the end plate. This integration eliminates the need for separate cavity formation steps and combines wiring installation with insulation preparation, simplifying the overall manufacturing process while maintaining enhanced insulation performance
3Reliability
If insulating material is poured into pouring cavities and solidified to cover insulated treatment positions, then the insulation capability is strengthened, but the manufacturing time and process steps increase
Solution Approach 1:
The patent applies preliminary action by pre-forming the pouring cavities as integral parts of the wiring board structure before assembly. The cavities are ready to receive insulating material immediately upon mounting the wiring board to the end plate, eliminating the need for time-consuming cavity formation steps during final assembly and reducing overall manufacturing time
Solution Approach 2:
The patent segments the insulation treatment into discrete pouring cavities located at specific insulated treatment positions, allowing insulating material to be poured into individual cavities rather than requiring complete immersion or complex coating processes. This segmentation enables targeted, efficient insulation application that reduces material waste and processing time
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 enhanced insulation design effectively addresses the increased voltage requirements, providing improved safety and stability for motor stators in vehicular compressors operating in conductive environments.
Implementation Method 1
the insulating material is poured into the respective pouring cavity and solidified to cover the insulated treatment position
Data Source
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AI summary
The present disclosures provides a motor stator, a motor, and an vehicular compressor, a motor stator comprising: a stator core; a first insulated end plate and a second insulated end plate mounted at opposite end surfaces of the stator core; a wire wrapping around the stator core and the first and second insulated end plates, the wire having a conducting core and an insulated outer sheath; a wiring board mounted to an axial outer side of the first insulated end plate; wherein the first insulated end plate comprises a plurality of insulated treatment positions and a plurality of casing portions through which to be addressed various portions of the wiring boards, the plurality of wiring boards to be fed to be insulated. Products according to examples of the present disclosure provide better insulation.