Plastic Winding Carrier Grooves for Stator Insulation

Solution Overview

Problem

In compact pump assemblies with electric drive motors, adequately insulating connection wires between stator windings and metallic stator housings is challenging due to the compact construction.

Innovation Solution

A stator arrangement with a plastic winding carrier featuring grooves that house electrical conductors connecting windings, providing insulation by keeping the conductors away from metal parts, eliminating the need for additional insulation and allowing for a compact motor design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If connection wires are arranged on the winding carrier to connect diametrically oppositely lying coils, then the windings can be electrically connected in series, but adequate electrical insulation from the metallic stator housing becomes difficult to achieve

Engineering Contradiction:

Improveelectrical insulationVSAvoidinsulation structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The groove acts as an intermediary structure between the connection wire and the metallic stator housing. The plastic material of the groove serves as the insulating medium, physically separating the conductive elements from the metal housing without requiring additional insulation layers or complex insulating structures.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The insulation function is merged into the winding carrier structure itself through the groove. Instead of being a separate component, the insulating feature is integrated directly into the plastic winding carrier, simplifying the overall structure while maintaining electrical insulation reliability.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If additional insulation is provided for connection wires, then electrical insulation is improved, but the motor construction becomes less compact

Engineering Contradiction:

Improveelectrical insulationVSAvoidmotor volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The insulation function is merged into the winding carrier structure itself through the groove. Instead of being a separate component, the insulating feature is integrated directly into the plastic winding carrier, simplifying the overall structure while maintaining electrical insulation reliability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The groove provides a thin-film-like insulating barrier using the plastic material of the winding carrier. This thin insulating structure is sufficient to prevent electrical breakdown while minimizing the space required, allowing compact motor construction without compromising insulation reliability.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If the distance between connection wires and the inner wall of the stator housing is increased, then electrical insulation is improved, but the motor construction becomes less compact

Engineering Contradiction:

Improveelectrical insulationVSAvoidradial distance

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

The groove acts as an intermediary structure between the connection wire and the metallic stator housing. The plastic material of the groove serves as the insulating medium, physically separating the conductive elements from the metal housing without requiring additional insulation layers or complex insulating structures.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The groove provides a thin-film-like insulating barrier using the plastic material of the winding carrier. This thin insulating structure is sufficient to prevent electrical breakdown while minimizing the space required, allowing compact motor construction without compromising insulation reliability.

Inventive Principle:

Principle #30Flexible shells and thin films

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

Ensures effective electrical insulation of connection wires while maintaining a compact motor construction, allowing the windings to be connected simply and securely without additional insulation, even in close proximity to metal components.

Implementation Method 1

Since the winding carrier is designed of plastic, such a side-wall of the groove can provide an adequate electrical insulation

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS10141806B2Stator arrangement

Publication Date: 2018.11.27 GRUNDFOS HLDG

AI summary

A stator arrangement for an electrical motor has several windings (28) which are arranged on a winding carrier (26) of plastic. A groove (32) extends in the peripheral direction and is open to the axial end-side and in which at least one electrical conductor (30) electrically connecting two of the windings (28) is arranged. The groove (32) is formed on at least one axial end-side (20) of the winding carrier (26). An electric motor including the stator arrangement as a pump assembly with such a stator arrangement are also provided.