Stator Insulator Single Fixed Piece Coil Latching

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Solution Overview

Problem

Conventional methods for producing stators with insulators and coils face issues such as high labor and cost due to multiple fixed pieces, and loosening of winding wires during resin injection, which affects performance and copper loss.

Innovation Solution

A method involving an insulator with a single fixed piece for latching the coil, allowing resin injection from the side of the fixed piece to prevent coil loosening and position the coil on the outer side of the stator core, reducing production costs and improving efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple fixed pieces are used to latch the coil, then the coil is securely held during resin injection, but the production cost and labor increase

Engineering Contradiction:

Improvecoil stability during resin injectionVSAvoidproduction cost and labor

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent extracts only the essential latching function needed to prevent coil loosening during resin injection. Instead of using multiple fixed pieces at both ends of the insulator, a single fixed piece is positioned strategically to provide sufficient latching while reducing part count, manufacturing complexity, and cost.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent inverts the conventional approach by positioning the single fixed piece at a specific location (one end of the insulator) rather than symmetrically at both ends. This asymmetric positioning is optimized to prevent coil loosening during resin injection from the opposite end, achieving security with fewer components.

Inventive Principle:

Principle #13The other way round (Inversion)

2Reliability

If resin is injected from the conventional side, then the insulation is maintained, but the coil may loosen due to resin pressure

Engineering Contradiction:

Improveinsulation performanceVSAvoidcoil position stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent applies preliminary anti-action by positioning the fixed piece to counteract the resin pressure before injection occurs. The fixed piece is strategically located to prevent coil loosening in advance, opposing the harmful effect of resin pressure that would otherwise cause the coil to shift or loosen during the injection process.

Inventive Principle:

Principle #9Preliminary anti-action

3Reliability

If the coil is positioned on the inner side of the stator core, then the insulation is adequate, but copper loss increases due to performance deterioration

Engineering Contradiction:

Improveinsulation adequacyVSAvoidcopper loss

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent inverts the conventional coil positioning by placing the coil on the outer side of the stator core instead of the inner side. This inversion, combined with the single fixed piece positioning, allows the coil to be securely held while positioned optimally to reduce copper loss and improve electrical performance, while still maintaining adequate insulation.

Inventive Principle:

Principle #13The other way round (Inversion)

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 results in a high-performance stator with reduced copper loss and lower production costs by using fewer fixed pieces, effectively suppressing coil loosening and improving the positioning of the insulator and coil on the outer side of the stator core.

Implementation Method 1

resin is injected into an injection gate Ma provided in the die M (in the Y direction). The resin is injected into regions around the teeth T, the insulators I, and the coils C.

Methodology Applied

Scientific EffectFluid pressure: Pressure Increase

Data Source

PatentUS9948166B2Method for producing stator

Publication Date: 2018.04.17 TOYOTA JIDOSHA KK

AI summary

A method that can produce a high-performance stator by providing only an upper or lower fixed piece for latching a coil on an insulator and thus effectively suppressing loosening of the coil winding wire when resin is injected while improving the production efficiency of the insulator. The method includes producing an intermediate by disposing a coil around an insulator, which includes a tubular portion, a flange at one end thereof, and a fixed piece that, when the insulator is loosely fit around the tooth, extends in the radial direction of the tooth from an end side of the flange corresponding to an upper or lower end face of the tooth, and has a coil latching claw, and loosely fitting the insulator with the coil around the tooth; and placing the intermediate in a die and injecting resin from around a region where the coil is latched by the fixed piece.