Stator Contact Adapter Potting for High-Voltage Conductor Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical refrigerant drives in motor vehicles face challenges in achieving simple and reliable electrical isolation of conductors, particularly in high-voltage applications, with complex and non-uniform welding regions impeding effective isolation.
Innovation Solution
A stator design featuring a stator core with a stator winding and a contact adapter that includes potting pockets, where phase connectors are inserted and surrounded by a cured potting material, ensuring electrical isolation and mechanical stabilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the stator winding is applied to the stator core in the form of individual coils welded to a contact or terminal unit, then the stator can be assembled, but the welded regions are not uniformly embodied which impedes isolation in the region of the motor
Solution Approach 1:
The patent introduces a potting material as an intermediary substance that fills the space between the stator winding coils and the contact/terminal unit. This potting material serves as a mediator that provides uniform electrical isolation without requiring direct welding contact, thereby resolving the contradiction between ease of assembly and reliable isolation.
Solution Approach 2:
The patent employs a simple, cost-effective potting material that can be easily applied and cured to provide isolation. This approach replaces complex welding procedures with a simpler, more reliable encapsulation method that ensures uniform isolation across all conductor regions.
2Productivity
If high currents are applied to the stator winding for rapid compressor start-up, then the compressor can be accelerated quickly, but significant heat is produced in the stator winding
Solution Approach 1:
The refrigerant is introduced as a thermal intermediary that flows through channels in the stator core, absorbing heat from the stator winding during high-current operation. This allows rapid compressor start-up while the refrigerant continuously removes the generated heat, preventing excessive temperature rise.
3Reliability
If a through connection is used to seal phase connectors between motor housing and electronics housing, then fluid-tight separation is achieved, but the structure becomes more complex
Solution Approach 1:
The patent combines the sealing function with the structural housing design by integrating sealing elements directly into the housing components. This merging of functions achieves fluid-tight separation between the motor housing and electronics housing while avoiding the need for separate, complex through-connection sealing structures.
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
The solution provides reliable and cost-effective electrical isolation, improved mechanical stability, and simplified assembly, while maintaining fluid-tight and pressure-tight separation in high-voltage environments.
Implementation Method 1
the potting pocket is filled with a cured potting material
Data Source
AI summary
A stator for an electrical refrigerant drive includes a laminated core wound with a stator winding, and a contact adapter mounted on the laminated core for connecting the stator winding to at least one phase connector. The contact adapter has at least one potting pocket and the phase connector is fitted in the potting pocket. A winding portion of the stator winding is guided into the potting pocket and contacted with the phase connector. The potting pocket is filled with a cured potting material. A motor vehicle electrical refrigerant drive having the stator is also provided.