Stator Spacer Reduces Resin Volume in Electric Motor
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Solution Overview
Problem
Conventional stators with molded resin outer covers in electric motors and air conditioners have high manufacturing costs due to excessive resin usage.
Innovation Solution
A stator design featuring winding sections arranged at equal intervals with spacers inserted between them, reducing the amount of resin needed for the molded outer cover by filling the spaces between these spacers with resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a molded resin outer cover is used to surround the stator core, then the stator achieves structural integrity and protection, but the manufacturing cost increases due to excessive resin usage
Solution Approach 1:
The stator is divided into distinct functional sections: the stator core, the winding sections, and the spacer. This segmentation allows the resin to be applied only where necessary for structural support, rather than forming a complete outer cover, thereby reducing resin usage while maintaining structural integrity.
Solution Approach 2:
The spacer is extracted as a separate component that performs the function of maintaining spacing between winding sections. By taking out this function into a dedicated spacer component, the resin is no longer needed to fill the entire space around the stator core, significantly reducing resin quantity while preserving structural support.
2Stability of the object's composition
If resin is used to fill spaces between winding sections, then structural support is provided, but manufacturing cost increases
Solution Approach 1:
The spacing function is extracted from the resin material and implemented through a dedicated spacer component. This allows the resin to be used only for bonding and sealing purposes, rather than filling entire spaces, reducing material costs and simplifying the manufacturing process.
Solution Approach 2:
The spacer acts as an intermediary component between the winding sections, providing the necessary spacing and structural support without requiring large amounts of resin. This intermediary element reduces the complexity of the manufacturing process and lowers material costs.
3Reliability
If a complete molded resin outer cover is formed around the stator core, then protection is achieved, but the amount of resin used increases
Solution Approach 1:
The protective structure is segmented into essential protection zones only, rather than forming a complete outer cover. The resin is applied selectively to provide protection where needed, reducing overall resin consumption while maintaining reliability.
Solution Approach 2:
The spacer is extracted as a separate protective and spacing component, eliminating the need for resin to fill the entire space around the stator core. This reduces resin consumption while maintaining the necessary protection and structural support.
Data Source
AI summary
A stator includes a plurality of winding sections circumferentially disposed at an equal interval; a spacer inserted into a space between the winding sections; and a resin section filling the space into which the spacer is inserted.