Stator Weld Insulation via Resin Molding
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Solution Overview
Problem
Existing stator insulation methods require excessive material and reduce coil cooling efficiency due to full coverage of coil end portions with resin, while methods that focus on welded portions require larger resin caps and adhesive application, reducing productivity.
Innovation Solution
An insulating resin coating method that uses resin-molding molds to specifically coat only the welds of coil wires, eliminating the need for adhesive application and reducing material usage by forming insulating resin only on necessary portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin molding is performed on the entire coil end portions, then the welded portions are insulation-coated, but a larger amount of material is required and coil cooling efficiency is low
Solution Approach 1:
The patent applies local quality by switching from full coil end portion coating to selective welded portion coating. The insulating resin is applied only to the specific areas where welded portions are located, rather than uniformly coating the entire coil end portion. This localized approach reduces material consumption while maintaining the insulation function where it is actually needed.
Solution Approach 2:
The patent extracts the insulation requirement from the entire coil end portion and applies it only to the welded portions. By separating the insulation need from the non-welded areas, the patent eliminates unnecessary material usage in regions that do not require insulation, thereby reducing the quantity of insulating resin while preserving reliability.
2Reliability
If resin molding is performed on the entire coil end portions, then the welded portions are insulation-coated, but coil cooling efficiency is low
Solution Approach 1:
The patent applies local quality by restricting insulating resin application to only the welded portions rather than the entire coil end portion. This localized insulation approach preserves the thermal pathways in the non-coated areas, allowing heat to dissipate more effectively from the coil while maintaining electrical insulation where required.
3Quantity of substance
If cap-shaped insulating resin is attached to each welded portion, then material usage is reduced, but the step of applying adhesive is required which reduces productivity
Solution Approach 1:
The patent replaces the mechanical adhesive application process with a direct resin molding process. Instead of attaching pre-formed cap-shaped insulating resin with adhesive, the insulating resin is applied directly to the welded portions through molding. This substitution eliminates the adhesive application step and associated curing time, thereby improving productivity while maintaining material efficiency.
Solution Approach 2:
The patent merges the insulating resin application with the welded portion formation process. By integrating the insulation coating into the same manufacturing sequence as welding, the patent eliminates separate operations for adhesive application and curing, thereby improving productivity without sacrificing material efficiency.
4Reliability
If insulating resin caps having larger size than welded portions are used, then all welded portions can be covered, but the step of applying adhesive is required which reduces productivity
Solution Approach 1:
The patent replaces the adhesive attachment mechanism with direct resin molding. Instead of using oversized caps that require adhesive for secure attachment, the insulating resin is molded directly onto the welded portions, creating a bonded insulation layer without requiring separate adhesive application or curing steps.
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 method allows for efficient insulation of welds without reducing productivity, minimizing resin usage and maintaining coil cooling efficiency by targeting only the necessary areas with the insulating resin.
Implementation Method 1
sandwiching and covering the weld of the coil wires by a pair of resin-molding molds
Implementation Method 2
injecting the resin into the resin-molding molds by the resin injector
Data Source
AI summary
An insulating resin coating method for coating with an insulating resin a weld of a stator having a plurality of the welds formed by welding ends of coil wires together, the method including the steps of: sandwiching and covering the weld of the coil wires by a pair of resin-molding molds; and injecting the resin into the resin-molding molds by a resin injector.