Stator Molding with Resin Chips to Reduce Material Usage
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Solution Overview
Problem
The existing methods for manufacturing stators in motors require significant amounts of molding resin, leading to high manufacturing costs, and there is a need for further reduction in resin usage to optimize costs.
Innovation Solution
A stator design that includes a stator core with adjacent teeth, a coil wound around these teeth, and a resin chip placed between the coil winding portions, which is then covered with a molding resin, reducing the overall resin usage by integrating resin chips from previous molding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a ring shaped groove is provided at an axial end surface of a stator to reduce the amount of use of molding resin, then the manufacturing cost is reduced, but the resin distribution uniformity and structural integrity may be compromised
Solution Approach 1:
The molding resin is divided into two parts: resin chips placed in the gap between winding portions and molding resin injected into the cavity. This segmentation allows the resin chips to occupy space that would otherwise require injected resin, reducing the total amount of molding resin needed while maintaining uniform distribution through the combination of pre-placed chips and injected resin filling gaps.
Solution Approach 2:
Resin chips are placed in the gap between winding portions before the molding resin injection process. This preliminary action ensures that the resin chips are already in position to reduce resin usage, and the subsequent injection of molding resin fills the remaining spaces, achieving both cost reduction and uniform resin distribution.
2Quantity of substance
If resin chips are placed in gaps between winding portions, then the amount of molding resin is reduced, but the complexity of the manufacturing process increases
Solution Approach 1:
Resin chips are placed in the gap between winding portions before the molding resin injection process. This preliminary action ensures that the resin chips are already in position to reduce resin usage, and the subsequent injection of molding resin fills the remaining spaces, achieving both cost reduction and uniform resin distribution.
Solution Approach 2:
The resin chips serve a dual function: they reduce the total amount of molding resin needed and simultaneously act as positioning elements that guide the flow of molding resin during injection. This self-service approach reduces process complexity by having the resin chips perform multiple functions without requiring additional manufacturing steps.
3Quantity of substance
If the amount of molding resin is reduced, then the manufacturing cost is reduced, but the reliability of the stator structure may be compromised
Solution Approach 1:
The molding resin is divided into two parts: resin chips placed in the gap between winding portions and molding resin injected into the cavity. This segmentation allows the resin chips to occupy space that would otherwise require injected resin, reducing the total amount of molding resin needed while maintaining uniform distribution through the combination of pre-placed chips and injected resin filling gaps.
Solution Approach 2:
The stator structure uses a composite approach combining resin chips (solid resin pieces) with molding resin (injected liquid resin that cures). This composite material system maintains structural integrity by having the resin chips provide internal support and the molding resin provide external bonding, achieving both cost reduction and reliability.
Data Source
AI summary
The stator includes a stator core having a first tooth and a second tooth adjacent to each other, a coil having a first winding portion wound around the first tooth and a second winding portion wound around the second tooth, a resin chip disposed in in a gap between the first winding portion and the second winding portion, and a molding resin covering the stator core, the coil, and the resin chip.