Stator Insulating Film Concave Section for Paint Adhesion
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Solution Overview
Problem
Conventional stators face issues with decreased adhesive properties between insulating films and protective paints, leading to peeling and exposure of conductors, which compromises insulating performance and limits material selection flexibility.
Innovation Solution
A stator design featuring a concave section on the insulating film surface, allowing the protective paint to enter and anchor, increasing contact area and adhesive properties, and using polyimide films with hollow capsules to enhance adhesion without additional processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coating method is used, then insulating performance can be achieved, but adhesive property between insulating film and protective paint decreases
Solution Approach 1:
The concave sections are formed on the insulating film surface before the protective paint is applied. This preliminary structural modification creates anchor points that enhance adhesion when the paint is subsequently coated, allowing the paint to mechanically interlock with the film surface rather than relying solely on chemical adhesion.
Solution Approach 2:
The insulating film is designed with a porous or textured surface structure featuring concave sections. This increased surface area and porosity allows the protective paint to penetrate and anchor into the concave regions, significantly improving the adhesive bond between the paint layer and the insulating film.
2Strength
If material combination is restricted for adhesion, then adhesive property improves, but degree of freedom in material selection decreases
Solution Approach 1:
By pre-forming the concave sections on the insulating film surface, the adhesion mechanism is changed from relying on material compatibility to relying on mechanical interlocking. This allows any insulating film material to be paired with any protective paint material, as long as the paint can be applied to and penetrate the concave structure.
Solution Approach 2:
The porous surface structure with concave sections provides a universal adhesion mechanism that works with diverse material combinations. The mechanical anchoring effect in the concave regions compensates for poor chemical adhesion between incompatible materials, enabling broad material selection freedom.
3Reliability
If protective paint is coated over conductor segment and insulating film, then insulating performance is secured, but peeling and raising occur
Solution Approach 1:
The concave sections create a textured, porous surface that allows the protective paint to mechanically interlock with the insulating film. This interlocking structure prevents the paint from peeling or raising, maintaining the integrity of the paint film even when coated over the conductor segment and insulating film combination.
Solution Approach 2:
The concave sections are formed beforehand to create anchor points that prevent future peeling. This preliminary structural preparation ensures that when the protective paint is applied, it becomes firmly anchored and resists peeling and raising under operational conditions.
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 design improves the adhesive properties between the insulating film and protective paint, minimizing peeling and exposure, ensuring reliable insulating performance and simplifying material selection while maintaining high insulating integrity.
Implementation Method 1
a concave section is formed in a surface of the insulating film, and the protective paint enters the concave section
Data Source
AI summary
A stator includes a stator core, and a coil mounted on the stator core and having an insulating film, at least a part of the insulating film being coated with a protective paint, wherein a concave section is formed in a surface of the insulating film, and the protective paint is present in the concave section. The insulating film has hollow capsules formed therein.