Stator Winding Insulation Curing with Staggered Glass Transition Resins

Solution Overview

Problem

Existing methods of forming insulation layers on stator windings using different electrical insulation resins with varying glass transition temperatures can lead to excessive heating, causing damage such as cracking and peeling due to mismatched curing temperatures.

Innovation Solution

A manufacturing method where a first insulation resin with a higher glass transition temperature is applied and cured at elevated temperatures, followed by a second resin with a lower glass transition temperature, utilizing the residual heat of the windings to avoid excessive reheating and minimize stress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a first electrical insulation resin with higher glass transition temperature is cured at high temperature, then the first insulation layer is properly formed, but subsequent curing of a second resin requires excessive reheating causing damage

Engineering Contradiction:

Improvecuring quality of first insulation layerVSAvoiddamage to insulation layers from excessive heating

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The first insulation layer is formed in advance using a resin with high glass transition temperature that can withstand subsequent high-temperature curing of the second resin. This preliminary action ensures that when the second resin requires high-temperature curing, the first layer is already damage-resistant.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the parameter of glass transition temperature between the two resins. The first resin has a higher glass transition temperature than the second resin, allowing the first resin to remain stable during the high-temperature curing process of the second resin without suffering from excessive heating damage.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If multiple insulation layers with different glass transition temperatures are formed sequentially, then proper insulation is achieved, but processing time increases due to multiple curing cycles

Engineering Contradiction:

Improveinsulation qualityVSAvoidtotal curing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The first insulation layer is formed in advance using a resin with high glass transition temperature that can withstand subsequent high-temperature curing of the second resin. This preliminary action ensures that when the second resin requires high-temperature curing, the first layer is already damage-resistant.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the parameter of glass transition temperature between the two resins. The first resin has a higher glass transition temperature than the second resin, allowing the first resin to remain stable during the high-temperature curing process of the second resin without suffering from excessive heating damage.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If high temperature curing is applied to ensure complete resin curing, then insulation performance is improved, but stress and deformation increase

Engineering Contradiction:

Improveinsulation performanceVSAvoidthermal stress in insulation layers

Core Design Contradiction:

ReliabilityVSStress or pressure

Solution Approach 1:

The patent utilizes the difference in glass transition temperatures between two resins to manage thermal stress. The first resin with higher glass transition temperature can withstand high-temperature curing of the second resin without deforming, thereby reducing thermal stress and preventing insulation layer damage while ensuring complete curing for optimal insulation performance.

Inventive Principle:

Principle #35Parameter changes

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 prevents damage to the insulation layers while reducing the overall time and cost by avoiding excessive heating and ensuring proper curing of both resins, thus ensuring robust and efficient insulation formation.

Implementation Method 1

curing the first electrical insulation resin at a temperature or temperatures higher than a glass transition temperature of the first electrical insulation resin

Methodology Applied

Scientific EffectGlass transition: Phase Change

Implementation Method 2

curing the second electrical insulation resin at a temperature or temperatures higher than a glass transition temperature of the second electrical insulation resin

Methodology Applied

Scientific EffectGlass transition: Phase Change

Data Source

PatentUS12573924B2Manufacturing method of stator

Publication Date: 2026.03.10 DENSO CORP

AI summary

A manufacturing method for a stator includes a first process and a second process. The first process includes: coating a first electrical insulation resin to windings of the stator; and curing the first electrical insulation resin at a temperature(s) higher than a glass transition temperature of the first electrical insulation resin. The second process includes: coating a second electrical insulation resin to the windings after the first process; and curing the second electrical insulation resin at a temperature(s) higher than a glass transition temperature of the second electrical insulation resin. The glass transition temperature of the first electrical insulation resin is higher than the glass transition temperature of the second electrical insulation resin.