Strip Shaped Stator Cores With Integrated End Insulators
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Solution Overview
Problem
Conventional motor stator core structures are complex to manufacture and prone to puncture due to incomplete isolation of non-insulators from the stator winding.
Innovation Solution
A strip-shaped stator structure with end insulators injection molded as a whole, featuring a wire duct with bosses for coil windings, a T-shaped column, clip, and arc surfaces for secure assembly and compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the end insulator is injection molded separately and then mounted onto the stator core, then the manufacturing process is simpler in terms of mold design, but the structure becomes complicated and difficult to make, and the stator has a risk of being punctured due to incomplete isolation
Solution Approach 1:
The patent merges the end insulator and stator core into a single integrated component through co-injection molding. The end insulator forms an integral part of the stator core structure, eliminating separate mounting operations and reducing structural complexity while maintaining manufacturing simplicity.
Solution Approach 2:
The integrated end insulator structure serves multiple functions simultaneously: it provides electrical insulation, structural support, and sealing isolation in a single component, thereby reducing overall device complexity while easing the manufacturing process.
2Ease of manufacture
If the end insulator is injection molded separately and then mounted onto the stator core, then the manufacturing process allows for separate production, but non-insulators cannot be completely isolated with the stator winding, thus the stator has a risk of being punctured
Solution Approach 1:
By combining the end insulator and stator core into a single molded structure, the patent achieves complete isolation of non-insulating materials from the stator winding. The integrated structure eliminates gaps and discontinuities that would exist in separately mounted components, ensuring puncture-free isolation while maintaining separate production capability through co-injection molding.
Solution Approach 2:
The end insulator is formed as part of the stator core structure during the molding process itself, before assembly. This preliminary formation ensures that the insulating structure is already in place and properly positioned, guaranteeing complete isolation and eliminating the risk of puncture during subsequent operations.
3Ease of operation
If conventional separate mounting method is used, then the assembly process is simpler, but the stator structure is complicated and difficult to make
Solution Approach 1:
The patent combines the end insulator and stator core into a single integrated component, which simplifies the assembly process by eliminating separate mounting operations. Although the molding process becomes slightly more complex, the overall manufacturing difficulty is reduced due to the elimination of multiple assembly steps and the resulting simplified structure.
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
Simplifies manufacturing, enhances slot filling ratio, prevents puncture, and facilitates easy assembly and disassembly of the control panel with reliable positioning.
Implementation Method 1
the end insulators are injection molded with the strip shaped stator cores as a whole
Implementation Method 2
coil windings wind around the bosses and pass through the wire duct
Data Source
AI summary
A stator structure, including strip shaped stator cores and end insulators. The end insulators are injection molded with the strip shaped stator cores, as a whole. A wire duct is arranged on top of a yoke of each strip shaped stator core and at the bottom of each end insulator. Two ends inside the wire duct are projected with bosses. Coil windings wind around the bosses and pass through the wire duct. The stator structure is simple and easy to mass produce. It can make full use of the slot filling ratio of the strip shaped stator. The invention solves the puncture problem.