Stator Connecting Portion Insulation to Prevent Bridge Formation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing stator designs face challenges in efficiently insulating connecting portions of shaped conductors, leading to potential dielectric breakdown, increased material costs, and inefficiencies due to full potting methods, which also hinder heat dissipation.
Innovation Solution
The design incorporates insulation elements with an additional cross-sectional area extending beyond the sides at corner portions, enhancing insulation efficiency and preventing bridge formation, while using a mold with blind holes to apply a flowable enveloping material for precise insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the immersion process is conducted to achieve greatest possible material thickness of insulation elements, then insulation efficiency is improved, but bridge formations between insulation elements of adjacent connecting portions occur
Solution Approach 1:
The insulation element is designed with locally varied thickness: greater thickness at corner portions (where highest electrical field strengths occur) and reduced thickness at side portions. This local differentiation ensures adequate insulation where needed while preventing bridge formations between adjacent connecting portions, thus resolving the contradiction between insulation efficiency and bridge formation risk.
2Object-generated harmful factors
If insulation elements are formed with small material thickness at corner portions, then bridge formations are prevented, but insulation efficiency at regions with greatest electrical field strengths is reduced
Solution Approach 1:
The insulation element features non-uniform thickness distribution with deliberately increased material thickness at corner portions compared to side portions. This local quality enhancement ensures that regions with greatest electrical field strengths (corner portions) receive superior insulation while maintaining overall reliability by preventing bridge formations in less critical areas.
3Reliability
If full potting is carried out to insulate all connecting portions, then insulation is achieved, but material costs increase and heat dissipation is hindered
Solution Approach 1:
Instead of applying insulation material to all connecting portions uniformly (full potting), the invention extracts and applies insulation selectively only to corner portions where electrical field strengths are highest. This targeted approach maintains necessary insulation reliability while significantly reducing material consumption and associated costs.
Solution Approach 2:
The insulation strategy focuses resources locally at corner portions rather than distributing material uniformly across all connecting portions. This local quality approach ensures insulation is provided where it is most needed (at corners with highest field strengths) while avoiding unnecessary material usage in less critical areas, thus reducing overall material costs.
4Reliability
If full potting is used to insulate connecting portions, then insulation is achieved, but efficiency losses occur during operation due to hindered heat dissipation
Solution Approach 1:
The invention extracts the insulation function from a comprehensive full-potting approach and concentrates it only at corner portions. This selective insulation maintains electrical reliability while leaving side portions and other areas open for heat dissipation, thereby reducing energy losses during operation.
Solution Approach 2:
By providing insulation locally at corner portions rather than uniformly across all connecting portions, the invention maintains necessary electrical insulation where field strengths are highest while preserving heat dissipation pathways in other areas, thus minimizing efficiency losses during operation.
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 approach effectively prevents dielectric breakdown, reduces material usage, and maintains high insulation efficiency with improved heat dissipation, offering a cost-effective and tolerant compensation for manufacturing variations.
Implementation Method 1
The UV irradiation causes the enveloping material to transform from the flowable state into the solid form
Implementation Method 2
a plurality of insulation elements which each envelop at least one of the connecting portions and which are each formed from an electrically insulating material
Data Source
AI summary
Stator for an electric machine includes a stator core which has an axial end side, and a a plurality of shaped conductors which protrude from the stator core at the end side and which each have, at the end side, at least one end portion having a free end of the shaped conductor. Arrangements of at least two of the end portions are connected to one another in an electrically conductive and mechanical manner in such a way that each arrangement forms a connecting portion which has a first cross-sectional area that lies in a predefined cross-sectional plane and that has corner portions and side portions lying between the corner portions. A plurality of insulation elements each envelop at least one of the connecting portions and are each formed from an electrically insulating material.