Stator Wire Layout to Prevent Thin Resin Insulation Breakage
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Solution Overview
Problem
The insulation properties of the resin portion in a stator are compromised due to the breakage of a thin resin layer formed between the input terminal portion and the power wire, which are disposed facing each other in the radial direction, leading to reduced durability.
Innovation Solution
The lead wire and power wire portions are extended from the resin portion in a manner that they are separated by a distance greater than the maximum clearance width, preventing the formation of a thin resin layer by incorporating an extended portion separating portion, such as an offset portion, to maintain insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the input terminal portion and power wire are disposed facing each other in the radial direction inside the resin mold, then the space utilization is improved, but the resin layer thickness between them becomes very small leading to low durability
Solution Approach 1:
The invention changes the spatial arrangement from a radial facing configuration (2D planar arrangement) to a three-dimensional configuration where the lead wire portion and power wire portion are separated in multiple dimensions. The lead wire portion is positioned axially offset and radially displaced, creating a 3D separation that increases the resin layer thickness while still achieving compact space utilization through vertical stacking.
Solution Approach 2:
The resin mold acts as an intermediary material that fills and protects the clearance between the lead wire portion and power wire portion. By ensuring the clearance is sufficiently large, the resin mold can form a resin layer with adequate thickness to provide reliable insulation and mechanical protection, preventing direct contact between conductive parts.
2Manufacturing precision
If the clearance between the input terminal portion and power wire is reduced, then the manufacturing precision requirement is improved, but the resin layer thickness decreases leading to breakage under stress
Solution Approach 1:
Instead of controlling clearance in a single radial dimension, the invention introduces axial and radial offsets to create multi-dimensional separation. This transforms the problem from controlling a small radial clearance to managing a larger three-dimensional clearance volume, which is more tolerant to manufacturing variations and produces a thicker, stronger resin layer.
Solution Approach 2:
The invention changes the clearance parameters from a small radial gap to a larger three-dimensional clearance with specified axial and radial offsets. This parameter change ensures the resin layer thickness is sufficient to withstand operational stresses while maintaining acceptable manufacturing precision through standardized offset dimensions.
3Device complexity
If the lead wire portion and power wire portion are positioned close to each other, then the device complexity is reduced, but the insulation properties decrease due to thin resin layer formation
Solution Approach 1:
The invention maintains simple wire arrangements by using standard axial and radial offsets that are easy to implement in the winding process. The three-dimensional separation achieved through these offsets provides adequate insulation without requiring complex wire routing or positioning mechanisms, thus maintaining low device complexity while improving reliability.
4Reliability
If the resin layer thickness is increased to prevent breakage, then the durability is improved, but the space utilization decreases due to larger clearance requirements
Solution Approach 1:
The invention achieves adequate resin layer thickness by utilizing three-dimensional space through axial and radial offsets, rather than increasing clearance in a single radial dimension. This allows the resin layer to be sufficiently thick for durability while maintaining compact overall dimensions and efficient space utilization through vertical and radial positioning.
Data Source
AI summary
In this stator, lead wire extended portions and a power wire extended portion are extended from a resin portion by an extended portion separating portion such that the lead wire extended portions are separated from the power wire extended portion by distances that are greater than a maximum value of the width of clearance between an end-side portion of the lead wire extended portion and a facing portion located next to the end-side portion, the resin portion being provided so as to cover lead wire portions and a power wire portion.