Stator Slot Insulation Sheet for Low-Resistance Wire Insertion
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Solution Overview
Problem
The use of foamed resin in insulation sheets for stators results in high resistance when inserting winding wires, reducing workability, and increasing clearance, which restricts the design of the magnetic circuit and lowers heat conductivity.
Innovation Solution
The insulation sheet is configured with a foaming adhesive on the surface facing the inner wall of the slot and a non-foaming adhesive on the surface facing the winding wire side, allowing for easy insertion and close contact after assembly, thereby maintaining heat conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If foamed resin is used in an insulation sheet, then heat conductivity between the stator and winding wire is improved, but resistance when inserting the winding wire into the slot increases and workability is reduced
Solution Approach 1:
The insulation sheet is divided into two distinct regions: a first region with foamed resin for heat dissipation and a second region without foamed resin for easy wire insertion. This segmentation allows each region to fulfill its specific function without compromising the other, resolving the contradiction between heat conductivity and workability.
Solution Approach 2:
Different regions of the insulation sheet are assigned different material properties: the first region has high heat conductivity due to foamed resin, while the second region has low resistance for wire insertion by excluding foamed resin. This local differentiation of quality enables simultaneous achievement of thermal performance and assembly ease.
2Ease of operation
If clearance between the slot and winding wire is increased to reduce insertion resistance, then workability is improved, but heat conductivity between the coil and stator is lowered
Solution Approach 1:
The insulation sheet creates a localized clearance zone in the second region without foamed resin, allowing easy wire insertion, while the first region with foamed resin maintains thermal contact. This spatial segmentation of clearance and thermal contact zones resolves the contradiction between insertion ease and heat conductivity.
3Temperature
If foamed resin is used to bring the stator and winding wire into close contact, then heat conductivity is improved, but resistance during insertion process increases
Solution Approach 1:
The insulation sheet is segmented into a first region with foamed resin that provides thermal contact and a second region without foamed resin that facilitates assembly. This segmentation allows the manufacturing process to proceed easily while still achieving the desired thermal contact in the appropriate region.
Solution Approach 2:
The insulation sheet exhibits local quality differentiation where the first region provides high heat conductivity through foamed resin while the second region provides ease of assembly by excluding foamed resin. This localized functional differentiation resolves the contradiction between thermal performance and manufacturing ease.
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 configuration improves workability during assembly by reducing insertion resistance and ensures close contact between the winding wire and the slot, minimizing clearance, and enhances motor efficiency by preserving heat conductivity.
Implementation Method 1
the foaming adhesive that is thermally cured while foaming by heating is disposed on the first adhesive layer
Implementation Method 2
the foaming adhesive that is thermally cured while foaming by heating
Data Source
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AI summary
A stator including, a stator core having a slot, a winding wire to be inserted into the slot; and an insulation sheet interposed between the slot and the winding wire and configured to electrically insulate an inner wall of the slot and the winding wire, wherein the insulation sheet includes an insulation paper, a first adhesive layer disposed on a front surface of the insulation paper facing the inner wall of the slot, and a second adhesive layer disposed on a back surface of the insulation paper facing the winding wire, a foaming adhesive to be thermally cured while foaming by heating is disposed on the first adhesive layer, and a non-foaming adhesive having lower viscosity than that of the foaming adhesive when unheated is disposed on the second adhesive layer.