Stator Core with Varied Lamination Shapes for Wire Insulation

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Solution Overview

Problem

The existing stator designs in electric motors require additional insulating members to prevent wire contact, which increases manufacturing time, reduces winding efficiency, and degrades heat radiation performance due to restricted wire region and insulation limitations.

Innovation Solution

A stator formed by stacking steel plates with varying thicknesses to create a smooth, curved surface for wire winding, eliminating the need for additional insulating members by using inside and outside protruding portions that gradually decrease in thickness, allowing efficient wire accommodation and improved heat dissipation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an insulating member is provided between the stator and electric wire, then insulating performance is improved, but manufacturing time increases and heat radiation performance deteriorates

Engineering Contradiction:

Improveinsulating performanceVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The stator tooth portion itself provides the insulating function through its structural design (protruding portions and grooves), eliminating the need for separate insulating members. The stator structure serves both its primary function and the insulating function simultaneously.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Insulating resin is applied only in specific locations (grooves between protruding portions) rather than coating the entire tooth portion, providing necessary insulation while minimizing interference with wire winding and heat radiation.

Inventive Principle:

Principle #3Local quality

2Reliability

If an insulating member is provided between the stator and electric wire, then insulating performance is improved, but winding efficiency is reduced

Engineering Contradiction:

Improveinsulating performanceVSAvoidwinding efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The stator structure itself creates the insulating effect through its geometric features, allowing wire winding to proceed without additional insulating components that would restrict the winding region or complicate the process.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Instead of adding an insulating layer on top of the stator surface, the design inverts the approach by creating insulating grooves within the stator structure, allowing wire to be wound over the protruding portions without contact insulation barriers.

Inventive Principle:

Principle #13The other way round (Inversion)

3Reliability

If an insulating member is provided between the stator and electric wire, then insulating performance is improved, but heat radiation performance deteriorates

Engineering Contradiction:

Improveinsulating performanceVSAvoidheat radiation performance

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The stator structure provides insulation through its own geometry rather than through an additional thermal barrier, maintaining direct thermal contact between the wire and stator for effective heat radiation while still providing electrical insulation.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Insulation is provided only in localized grooves rather than as a continuous coating, preserving large areas of direct thermal contact between the wire and stator surface for efficient heat dissipation.

Inventive Principle:

Principle #3Local quality

4Productivity

If steel plates with varying thicknesses are stacked to create curved surfaces, then wire winding efficiency is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvewiring efficiencyVSAvoidstator structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The stator is constructed by stacking multiple steel plates with progressively varying thicknesses to form the curved surface and protruding portions, breaking down the complex shape into simpler manufacturable components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The steel plates are designed with curved surfaces and varying thicknesses to create the protruding portions and grooves, providing a smooth geometry that facilitates wire winding while maintaining structural integrity.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS9203270B2Stator core with varied lamination shapes and sizes to reduce wire insulation stress

Publication Date: 2015.12.01 SANYO DENKI CO LTD

AI summary

A stator is provided. The stator includes a yoke part of an annular shape, tooth winding portions that protrude inward from the yoke part and around which an electric wire is wound, and a tooth end portion formed on an inward side of the tooth winding portion. The stator is formed by stacking steel plates in a direction corresponding to a rotational axis of a motor. The tooth winding portion is formed by stacking the steel plates having different shapes such that at an end portion in the stacking direction, thickness of the tooth winding portions gradually decrease toward the end portion in the stacking direction, and the yoke part and the tooth end portion include protruding portions formed by stacking the steel plates, such that the protruding portions protrude from the tooth winding portion in the stacking direction.