Stator Segment With Plastic Webs and Insulation Layer
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Solution Overview
Problem
Existing stator manufacturing methods for electric motors are complex and costly, requiring additional insulation materials like insulating paper and welded connections, which complicate the assembly and reduce the structural integrity of the stator.
Innovation Solution
A stator segment design featuring a laminated core with injected plastic webs and layers for electrical insulation, which also serves as a cross-brace for increased stability, and end caps that interact with the plastic webs for enhanced cohesion, allowing for a single-step injection molding process that eliminates the need for additional connections and insulation materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating paper is inserted between the winding area and the laminated core for electrical insulation, then electrical insulation is achieved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The plastic layer serves dual functions: it provides electrical insulation between the winding area and laminated core, and simultaneously acts as a cross-brace for structural stability. This merging of insulation and bracing functions eliminates the need for separate insulating paper and welded connections, reducing assembly complexity while maintaining reliability
Solution Approach 2:
The plastic layer is designed to perform multiple functions within a single component: electrical insulation, structural cross-bracing, and axial cohesion. This multi-functionality replaces what would traditionally require multiple separate components (insulating paper plus welded connections), thereby reducing device complexity without compromising insulation performance
2Strength
If welded connections are used to connect laminated core sheets, then structural integrity is improved, but the manufacturing process becomes more complex and costly
Solution Approach 1:
The plastic layer replaces the mechanical welding process with a molding process. Instead of requiring post-assembly welding operations to connect laminated core sheets, the plastic layer is injection-molded to provide axial cohesion and structural integrity, thereby simplifying the manufacturing process while maintaining strength
Solution Approach 2:
The plastic layer is molded in advance to include axial cohesion features that pre-establish the structural connections between laminated core sheets. This preliminary action eliminates the need for subsequent welding operations, making the manufacturing process easier while ensuring structural integrity is achieved during the molding stage
3Reliability
If additional insulation materials and connections are used, then electrical insulation and structural stability are achieved, but the manufacturing cost increases
Solution Approach 1:
The plastic layer combines insulation and structural bracing functions into a single component, eliminating the need for separate insulating materials and welded connections. This reduction in component count directly lowers manufacturing cost while maintaining both electrical insulation and structural stability through the multi-functional design
Solution Approach 2:
By designing the plastic layer to perform multiple functions (insulation, cross-bracing, axial cohesion) simultaneously, the invention eliminates the need for multiple specialized components. This multi-functionality reduces material costs, assembly costs, and manufacturing complexity while ensuring both electrical insulation and structural stability are achieved
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 design enhances torsional and flexural rigidity while maintaining magnetic properties, simplifies the manufacturing process, and provides effective electrical insulation without the need for insulating paper, resulting in a more robust and cost-effective stator assembly.
Implementation Method 1
the laminated core having a plastic layer between the winding area of the stator winding and the laminated core for the electrical insulation of the winding region from the laminated core
Implementation Method 2
The advantage here is that increased torsional rigidity and flexural rigidity and at the same time electrical insulation can be produced by the plastic layer
Implementation Method 3
The plastic webs, plastic layer and end cap can be produced in a single work step, namely plastic injection molding
Data Source
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AI summary
The invention relates to a stator segment for a stator having a segmented design of an electric motor, to a stator composed of similar stator segments and to a method for producing a stator from stator segments, wherein the stator segment comprises a laminated core in which one or several plastic webs are injected which pass through the laminated core, the laminated core comprising a plastic layer that is arranged between the winding region of the stator winding and the laminated core for electrically insulating the winding region from the laminated core. According to the invention, the one or several plastic webs lead into a first end cap into which leads also the plastic layer.