Stator Insulating Member Projections for Resin Adhesion
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Solution Overview
Problem
The existing stators of electric rotating machines, particularly in vehicles, face insufficient adhering strength between the insulating sheet and the stator coil due to limited clearance between the slot side-wall and the insulating sheet, which can lead to movement of the insulating sheet and conductors under high power applications.
Innovation Solution
A stator design featuring a sheet-like electric insulating member with truncated conical via projections and through-holes that allow resin impregnation, providing firm adhesion to the stator core by filling resin into the clearances between the insulating member and the slot walls, enhancing mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulating sheet is formed with holes to allow varnish penetration, then the varnish can enter between electric conductors, but the adhering strength between the insulating sheet and stator coil remains insufficient due to limited clearance between slot side-wall and insulating sheet
Solution Approach 1:
The insulating sheet is segmented with multiple projections that extend into the slot, creating multiple localized adhesion zones. This segmentation allows the resin to penetrate and bond at multiple discrete points along the slot length, significantly increasing total adhesion area and strength despite limited overall clearance.
Solution Approach 2:
The insulating sheet transitions from a flat two-dimensional structure to a three-dimensional structure with projections extending radially into the slot. This dimensional change creates additional bonding surfaces and allows resin impregnation to occur in the radial dimension, dramatically improving adhesion without requiring increased slot width.
2Quantity of substance
If round wires are used as electric conductors, then there are many inter-conductor spaces for varnish penetration, but very little clearance exists between slot side-wall and insulating sheet
Solution Approach 1:
The projections act as intermediaries that bridge the gap between the insulating sheet and slot side-wall. These projections extend into the limited clearance space, providing pathways for resin penetration and creating bonding interfaces that overcome the insufficient radial clearance between the insulating sheet body and slot wall.
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 ensures a robust and stable adhesion of the insulating member to the stator core, preventing movement and ensuring reliable operation under high force conditions, particularly in high-power vehicle alternators.
Implementation Method 1
a resin filled in each of the slots so as to impregnate into the electric insulating member
Data Source
AI summary
The stator of a vehicle-use electric rotating machine includes a stator core having slots formed along a circumferential direction thereof, segment conductors having a rectangular cross section and wound on the stator core such that each of the slots accommodates at least two of the segment conductors to form a stator winding, a sheet-like electric insulating member disposed in each of the slots so as to surround the segment conductors accommodated in the slot, the electric insulating member being formed with a plurality of projections projecting toward a wall surface of the slot, and a resin filled in each of the slots so as to impregnate into the electric insulating member.