Stator Insulator Recess Layout to Protect Coil Coating During Welding
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Solution Overview
Problem
Existing motor technologies risk damaging the surface of the coating agent on coils due to welding spatter during the electrical connection of the coil and busbar unit, leading to potential defects and reduced manufacturing efficiency.
Innovation Solution
The motor device incorporates a recessed portion on the outer support wall of the insulator, allowing the coating agent to be applied through this gap between adjacent conductive members, preventing damage from welding spatter and ensuring even distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coil and busbar unit are electrically connected by welding after coating the coating agent on the coil, then the electrical connection is achieved, but the surface of the coating agent is damaged by welding spatter
Solution Approach 1:
The patent divides the stator structure into multiple segments including inner support walls and outer support walls that create separate zones. The coating agent is applied in a first region while the welding operation occurs in a second region, spatially separating the harmful welding spatter from the coated coil surface.
Solution Approach 2:
The patent introduces an intermediary structure (the support walls and the gap between them) that acts as a barrier between the welding operation and the coated coil surface. This intermediary prevents welding spatter from directly contacting and damaging the coating agent while still allowing the welding to proceed.
2Ease of manufacture
If the coating agent is coated on the coil after press-fitting the stator into the motor case, then the coating process is simplified, but the coating agent surface is exposed to welding spatter damage
Solution Approach 1:
The stator is segmented into inner and outer support walls that create distinct functional zones. This segmentation allows the coating agent to be applied to the coil in a protected first region, while the welding operation occurs in a separate second region, maintaining both manufacturing simplicity and coating protection.
Solution Approach 2:
The patent utilizes the axial dimension of the stator structure to create spatial separation. By positioning the coating application zone and welding zone at different axial locations separated by support walls, the design protects the coating from welding spatter while maintaining process simplicity.
3Reliability
If welding is performed to electrically connect the coil and busbar unit, then electrical connectivity is established, but manufacturing defects occur due to coating agent damage
Solution Approach 1:
The patent segments the stator structure into inner and outer support walls that define separate operational zones. This segmentation enables welding to occur in a protected manner that maintains electrical connectivity while preventing coating agent damage, thereby achieving both reliability and manufacturing precision.
Solution Approach 2:
The support walls are designed to preliminarily prevent welding spatter from reaching the coated coil surface before the welding operation occurs. This preliminary protective action ensures that the coating agent remains intact while the electrical connection is established through welding.
Data Source
AI summary
A motor device includes: multiple conductive members, provided on one side of a stator in an axial direction of a rotor, positioned across a first insulator split body toward a radial direction of the rotor, and connected to a winding start portion and a winding end portion of a coil; inner and outer support walls, provided on one side of the first insulator split body in the axial direction of the rotor and supporting the coil, which are wrapped around the first insulator split body, from inside and outside in the radial direction of the rotor; and a recessed portion, provided on the outer support wall, opening toward the inner support wall and the one side of the first insulator split body in the axial direction of the rotor. The recessed portion is configured between adjacent conductive members when the stator is viewed from one side in the axial direction.