Stator Core Insulator Assembly With Low-Heat Bus Bar Joining
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Solution Overview
Problem
Conventional electric motor stator assemblies face challenges in manufacturing and assembly due to fragile electrical insulation, high thermal resistance, and inefficient connection methods that can damage insulation and increase energy consumption, leading to reduced performance and safety risks.
Innovation Solution
The use of a thin, foldable insulator formed from materials like fish paper or polyimide film, which incorporates structural features for precise winding and mechanical protection, and a bus bar connection method using low-energy fasteners or crimping to attach wires without soldering or welding, reducing thermal resistance and assembly risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wire winding and connection methods are used, then electrical insulation is provided, but the insulation is fragile and susceptible to damage during assembly
Solution Approach 1:
The patent applies preliminary action by pre-attaching the electrical insulation to the core before wire winding occurs. The insulation is positioned and secured in advance, creating a protective layer that prevents damage during subsequent assembly operations. This eliminates the need for delicate handling of fragile insulation during wire installation.
Solution Approach 2:
The patent uses an intermediary approach by introducing a dedicated insulation component that acts as a mediator between the core and the wire. This insulation layer serves as a protective interface that prevents direct contact and potential damage between the wire and core, while also providing electrical isolation.
2Reliability
If soldering or welding is used to connect wires to bus bars, then strong electrical connections are achieved, but thermal resistance increases and energy consumption rises
Solution Approach 1:
The patent applies mechanics substitution by replacing the thermal-based connection methods (soldering and welding) with a mechanical compression connection system. The bus bar assembly uses compressive force to create low-resistance electrical contact between the wire and bus bar, eliminating the need for high-temperature thermal processes and associated energy consumption.
3Reliability
If thick insulation material is used, then electrical protection is improved, but thermal resistance increases and heat dissipation is reduced
Solution Approach 1:
The patent applies local quality by providing electrical insulation only at the specific locations where it is needed for electrical protection, rather than using thick insulation throughout. The insulation is strategically positioned at interfaces where electrical isolation is critical, while maintaining thin profiles in thermal pathways to enable efficient heat dissipation from the core.
Data Source
AI summary
A stator assembly typically includes at least one stator core assembly that generates a magnetic field to rotate a rotor. The stator core assembly includes a core and a coil wrapped around the core to receive a current thus generating the magnetic field. To improve the performance and manufacturability of the stator assembly, a stator core assembly may include an insulator, disposed between the coil and the core, formed as a single flat sheet. A flat manufacturing process allows greater control of the insulator geometry, a broader range of materials to form the insulator, and patterning of structural features into the insulator to improve assembly and performance. The coil of the stator core assembly may also be electrically coupled to a bus bar using a fastener process and/or a crimping process that consumes less energy and occurs at lower temperatures than conventional soldering or welding processes.