Stator Pole Tooth Assembly Injection Molding Insulation
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Solution Overview
Problem
Existing methods for producing stators for internal-rotor electric machines lack a compact design with optimal insulating properties, as they do not effectively connect individual electric machine coils and provide sufficient insulation against short circuits.
Innovation Solution
A method involving separate pole teeth with windings, forming a flexible ring-shaped assembly that is encapsulated in a plastic compound using injection molding, with tongue-and-groove connections and protective caps to ensure flexibility and insulation, and an outer ring for stabilization, allowing for a compact and well-insulated stator structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual pole teeth with windings are assembled to form a stator, then the stator can be produced with modular construction, but the insulation properties and compactness are insufficient due to large cavities between windings
Solution Approach 1:
Protective caps are placed on the pole teeth before the windings are wrapped around them. This preliminary action ensures that the pole teeth are protected from short circuits during the assembly process and maintains insulation properties while allowing modular construction to proceed
Solution Approach 2:
A connection element with a holding element and connecting element is introduced as an intermediary component between adjacent pole teeth. This connection element fills the cavity between windings, provides mechanical connection, and maintains insulation properties, thus resolving the contradiction between modular assembly and insulation reliability
2Stability of the object's composition
If pole teeth are connected rigidly to form a solid structure, then structural stability is improved, but flexibility during assembly and centering is reduced
Solution Approach 1:
The connection element is designed with a deformable connecting element that allows dynamic adjustment during assembly. The connecting element can be deformed to enable centering and positioning of the pole teeth, then stabilizes to provide structural rigidity once positioned, thus achieving both flexibility during assembly and structural stability in the final configuration
Solution Approach 2:
The connection element changes its physical parameters during assembly - it transitions from a deformable state during positioning to a rigid state for structural support. This parameter change allows the system to achieve both flexibility during assembly and structural stability in the final configuration
3Ease of manufacture
If the stator is produced with large cavities between windings for ease of assembly, then manufacturing is simplified, but the magnetic field strength and compactness are reduced
Solution Approach 1:
The connection element serves as an intermediary that fills the cavity between windings with insulating material. This eliminates large air gaps that would reduce magnetic field strength, while the connection element itself provides the necessary mechanical connection for assembly, thus achieving both ease of manufacture and strong magnetic field
Solution Approach 2:
The connection element combines insulating material with structural properties, creating a composite component that simultaneously provides electrical insulation to maintain magnetic field strength and mechanical connection for ease of assembly. The composite structure eliminates the need for separate insulating and connecting components
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 stator with enhanced insulation properties and a strong magnetic field in a compact physical space, preventing short circuits and ensuring a rigid structure with minimal cavity between windings, thus achieving superior electrical insulation.
Implementation Method 1
the flexible ring-shaped pole tooth assembly is introduced into an injection mold, centered there, and encapsulated by casting with a plastic compound
Implementation Method 2
The winding ends of the pole teeth are preferably connected to one another via a welding process
Data Source
AI summary
A method for producing a stator for an electrical machine as an internal rotor, in particular an electric motor. This method involves providing a multiplicity of separate pole teeth, which are wound. The ends of the winding wire of the pole teeth are connected to one another to create a flexible annular pole tooth assembly, and the flexible assembly is inserted into an injection mold and centered. The assembly located in the mold is encapsulated or sealed in a molding compound. In this way, a dimensionally stable stator with particularly good insulating properties can be produced.