Stator Vacuum Resin Injection for Ultra High Speed Motor
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Solution Overview
Problem
Super-high-speed induction motors face degradation due to heat generation and insulation deterioration, primarily caused by bubbles in heat conductive materials between the core and coil, leading to reduced performance and endurance.
Innovation Solution
An apparatus and method involving a mold with a vacuum and pressurizing system to remove bubbles from the functional resin, ensuring complete filling between the stator and mold, maximizing heat conductivity and insulation, and incorporating heating to decrease resin viscosity and solidification time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If functional resin is injected into the mold to fill the hollow space between core and coil, then heat conductivity and insulation are improved, but bubbles are created inside the resin and between resin and components, degrading heat conductivity
Solution Approach 1:
The patent applies vacuum treatment before resin injection to remove air from the mold cavity and from the resin itself. This preliminary removal of gases prevents bubble formation during and after resin injection, ensuring complete filling without voids that would degrade heat conductivity.
Solution Approach 2:
The patent uses vacuum pressure differential to remove bubbles from the resin. By creating a vacuum environment during resin injection and curing, bubbles rise and are removed from the resin mass, resulting in bubble-free heat conductive material filling.
2Temperature
If conventional cooling methods are applied to dissipate heat, then heat dissipation is achieved, but bubbles are created in the heat conductive material, causing localized temperature increase and thermal fracture
Solution Approach 1:
The patent performs vacuum treatment before heat conductive material injection to remove air from the mold and resin. This preliminary action prevents bubble formation that would later cause thermal fracture under operating temperatures, ensuring intact heat conduction paths.
Solution Approach 2:
The patent changes the pressure parameter by applying vacuum during resin injection and curing. This pressure change prevents bubble entrapment in the heat conductive material, eliminating potential sites for thermal fracture while maintaining effective heat dissipation.
3Productivity
If the mold is heated during vacuum and pressurizing steps, then resin viscosity decreases for efficient gas removal and solidification time decreases, but the process complexity increases
Solution Approach 1:
The patent combines the heating function with the existing vacuum chamber structure. The heating elements are integrated into the chamber walls or mold support structure, allowing simultaneous vacuum treatment and heating without requiring separate heating equipment, thus minimizing additional complexity.
Solution Approach 2:
The vacuum chamber is designed to serve multiple functions: creating vacuum for bubble removal, providing heating for resin viscosity reduction and curing, and enabling pressurizing for complete filling. This multi-functionality reduces the need for separate dedicated equipment for each process step.
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 effectively removes bubbles, enhances heat conductivity and insulation, and improves the performance and endurance of super-high-speed induction motors by ensuring complete resin filling and reduced solidification time.
Implementation Method 1
the vacuum step and the pressurizing step include heating the mold, in the vacuum step, the viscosity of the functional resin can be decreased
Implementation Method 2
converting the inside of the chamber into the vacuum state, and pressurizing the inside of the chamber is carried out so that bubbles are removed from the inside and the surface of the functional resin
Implementation Method 3
removing bubbles by increasing the gas pressure inside the chamber through a pressurizing tube
Data Source
AI summary
An apparatus and method for fabricating a stator of a super-high-speed induction motor, in which the process of loading a stator on which a coil is completely wound into a mold, injecting a functional resin into a chamber, converting the inside of the chamber into the vacuum state, and pressurizing the inside of the chamber is carried out so that bubbles are removed from the inside and the surface of the functional resin and the functional resin is completely filled between the inner circumference of the stator and the inner circumference of the mold, thereby maximizing heat conductivity and insulation, preventing the stator from deteriorating, and improving the performance and endurance of the super-high-speed induction motor. In addition, since the vacuum step and the pressurizing step include heating the mold, in the vacuum step, the viscosity of the functional resin can be decreased so that the process of removing gas inside the stator can be efficiently performed and the solidification time of the functional resin can be decreased so that the working time can be decreased, and in the pressurizing step, the molding that is under pressing force is completely solidified. Furthermore, the height of the receiving section of the mold and the height of the central shaft are adjusted so that the winding section of the stator is completely immersed, and the chamber is provided with a vacuum tube and a pressurizing tube in order to facilitate the step of injecting the functional resin and the pressuring step. The method includes (a) loading a stator having a coil, which is completely wound on a core, into a mold, (b) injecting a functional resin into the mold so that a winding section of the stator is immersed, (c) inserting the mold, into which the functional resin is injected, into a closed chamber, (d) removing bubbles by converting the inside of the chamber into a vacuum state through a vacuum tube, which is provided in the chamber, so that the functional resin is filled across the entire portions of the stator, including the core and the coil, and between the inner circumference of the stator and the inner circumference of the mold, and (e) removing bubbles by increasing the gas pressure in the chamber, so that the functional resin is filled across the entire portions of the stator, including the core and the coil, and between the inner circumference of the stator and the inner circumference of the mold.