Stator Slot Encapsulation via Injected Polymer
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Solution Overview
Problem
The voids created between adjacent stator teeth in electric motors by coil windings inhibit thermal conduction, leading to unacceptable heat buildup and potential motor failure due to prolonged high winding temperatures.
Innovation Solution
Filling these voids with a thermally conductive filler compound, injected under pressure to fully or substantially encapsulate the stator windings, which enhances heat conduction from the windings to the stator teeth, using thermally conductive plugs to seal gaps and ensure a smooth surface for efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coil windings are wound around stator teeth, then electrical functionality is achieved, but voids are created between adjacent portions of the conductive wire which inhibit thermal conduction
Solution Approach 1:
A thermally conductive filler compound is introduced as an intermediary material between the coil windings and the stator teeth. This filler compound fills the voids and interstitial spaces created by the winding process, providing a thermal conduction pathway from the windings to the stator teeth, thereby resolving the heat buildup problem while preserving electrical functionality.
Solution Approach 2:
The thermal conductivity parameter of the stator assembly is improved by changing the material composition in the void spaces. By replacing air (poor thermal conductor) with a thermally conductive filler compound, the overall thermal conduction capability of the stator structure is enhanced, allowing efficient heat dissipation from the windings.
2Ease of manufacture
If voids are left between coil windings, then winding process is simple, but thermal conduction from windings to stator is inhibited
Solution Approach 1:
The thermally conductive filler compound is introduced into the voids before the final curing or setting stage. This preliminary action ensures that the thermal conduction pathways are established early in the manufacturing process, allowing heat dissipation to be optimized without requiring complex modifications to the winding process itself.
3Temperature
If thermally conductive filler compound is injected to fill voids, then thermal conduction is improved, but manufacturing process complexity increases
Solution Approach 1:
The thermally conductive filler compound is injected into the stator using pneumatic or hydraulic injection systems. This method allows the filler material to be forced into the voids and interstitial spaces under pressure, ensuring complete filling while using automated injection equipment that can be integrated into existing manufacturing lines, thereby limiting the increase in manufacturing complexity.
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 method effectively improves thermal conduction, maintaining acceptable stator temperatures and preventing motor deterioration by ensuring efficient heat dissipation, with the filler compound achieving 100% filling at the center and greater than 90% filling at the ends of the stator.
Implementation Method 1
The thermally conductive filler compound may then be allowed to set... enhances heat conduction from the windings to the stator teeth
Implementation Method 2
A thermally conductive filler compound may be injected into each gap under sufficient pressure to at least substantially fill the interstitial spaces within each gap
Data Source
AI summary
A method for improving thermal conduction in a stator having electrically conductive windings wound in a plurality of gaps formed between adjacent pairs of a plurality of teeth of the stator. A plurality of interstitial spaces are formed within each of the gaps during winding of the electrically conductive windings around the teeth. A plug is arranged within each one of the gaps to close off slot openings. A thermally conductive filler compound is injected into each gap under sufficient pressure to at least substantially fill the interstitial spaces within each gap and to at least substantially encapsulate the electrically conductive windings. The thermally conductive filler compound is then allowed to set.