Motor Stator Insulation Segmentation for Winding Space
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Solution Overview
Problem
Conventional motor stators require separate molds for upper and lower insulators, leading to increased plastic material usage and reduced coil winding spaces due to fixed insulator thickness, which complicates manufacturing and affects efficiency.
Innovation Solution
A stator design featuring upper and lower insulators with thin thickness and partial coverage of the stator core, along with insulation films inserted between them, allowing for variable stacked heights without separate molds and increasing coil winding spaces through ultrasonic welding and locking mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If upper and lower insulators are made through plastic injection molding with predetermined thickness, then insulation performance is ensured, but the slots between teeth become narrow reducing coil winding spaces
Solution Approach 1:
The insulator system is segmented into three components: upper insulator, lower insulator, and slot insulation films. The slot insulation films are thin flexible films inserted into slots to provide insulation, while upper and lower insulators provide structural support. This segmentation allows each component to be optimized independently - the thin films minimize slot space occupation while maintaining insulation performance.
Solution Approach 2:
Thin flexible insulation films are used to line the slots between teeth instead of thick rigid plastic insulators. These thin films provide the necessary insulation performance while occupying minimal space, thereby enlarging the coil winding spaces within the slots.
2Reliability
If upper and lower insulators completely cover the teeth of stator core, then insulation coverage is maximized, but plastic material usage increases
Solution Approach 1:
The insulation system is divided into slot insulation films that line individual slots and upper/lower insulators that provide partial coverage. This segmentation allows insulation to be applied only where electrically necessary (inside slots and at tooth tips) rather than covering entire tooth surfaces, reducing plastic material usage.
Solution Approach 2:
Instead of completely covering all tooth surfaces with thick insulators, the design applies insulation partially - thin films inside slots and targeted coverage at tooth tips by upper and lower insulators. This partial action provides sufficient insulation coverage for electrical safety while minimizing plastic material consumption.
3Adaptability or versatility
If stacked heights of stator core are varied, then motor design flexibility is improved, but separate molds must be manufactured for upper and lower insulators increasing manufacturing complexity
Solution Approach 1:
The upper and lower insulators are designed as universal components that can accommodate multiple stator core stacked heights. The insulators function both as structural support elements and as insulation barriers, and their design allows them to work with different height configurations without requiring separate molds, thereby reducing manufacturing complexity.
Solution Approach 2:
The insulator system is designed to be adaptable to dynamic variations in stator core height. The slot insulation films can be cut to different lengths, and the upper/lower insulators are positioned to accommodate height variations, allowing the same mold designs to produce insulators that work across a range of stacked heights.
4Strength
If upper and lower insulators are made with substantial thickness, then structural strength is ensured, but the spaces for coil winding are reduced
Solution Approach 1:
The structural support function is assigned to the upper and lower insulators which are positioned at the ends of the stator core, while the slot insulation films provide electrical insulation within the slots. This functional segmentation allows the end insulators to bear the structural load with their thickness, while the slot films remain thin to maximize winding space.
Solution Approach 2:
Different parts of the insulation system have different thickness characteristics tailored to their specific functions. The upper and lower insulators have substantial thickness at the end positions where structural strength is needed, while the slot insulation films have minimal thickness where coil winding space is critical. This local differentiation of quality optimizes both strength and space utilization.
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 reduces plastic material usage, allows for variable stator core heights without additional mold manufacturing, and enlarges coil winding spaces, enhancing efficiency and cost-effectiveness.
Implementation Method 1
each of the insulation films is attached on the side of the back yoke or the sides of the teeth of the stator core contacted therewith by means of ultrasonic welding
Data Source
AI summary
The present invention relates to a stator for a motor including: a stator core having an annular back yoke and a plurality of teeth; an upper insulator having an annular body portion formed correspondingly to the back yoke of the stator core and a plurality of teeth insulation portions formed correspondingly to the teeth of the stator core so as to cover the upper sides of the teeth of the stator core; a lower insulator having an annular body portion formed correspondingly to the back yoke of the stator core and a plurality of teeth insulation portions formed correspondingly to the teeth of the stator core so as to cover the upper sides of the teeth of the stator core; a plurality of insulation films each adapted to be inserted into the slot to cover the side of the stator core exposed to the inside of the slot between the upper insulator and the lower insulator; and coils adapted to be wound on the teeth of the stator core enclosed by the upper insulator, the lower insulator and the insulation films.