Tooth-Shaped Stator Insulation for Direct Cooling
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Solution Overview
Problem
Traditional electric motor slot wall insulations face a trade-off between thermal conductivity and castability, with easily cast plastics having poor thermal conductivity and vice versa, and the impregnation process is inefficient due to poor access and wetting issues, limiting heat dissipation and power output.
Innovation Solution
A tooth-shaped slot wall insulation configuration is formed on the stator laminated core during injection molding, which fixes electrical conductors in place and creates fluid ducts for direct cooling, allowing for improved heat dissipation without additional impregnation and using less thermally conductive materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If filler material is added to increase thermal conductivity of plastic slot wall insulation, then thermal conductivity is improved, but flowing properties during injection molding deteriorate
Solution Approach 1:
The patent employs composite materials by combining plastic with thermally conductive filler particles to create a slot wall insulation material that achieves high thermal conductivity while maintaining adequate flow properties for injection molding. The composite structure allows the base plastic to provide flowability while the filler particles provide thermal conduction pathways.
Solution Approach 2:
The patent optimizes the parameters of the plastic material by adjusting the type, amount, size, and distribution of filler materials to achieve the desired balance between thermal conductivity and flow properties. By carefully controlling these parameters, the material can be molded effectively while providing sufficient heat dissipation.
2Reliability
If impregnation material is applied to wet electrical conductors and slot wall insulation, then mechanical movement prevention is improved, but process control and quality deteriorate due to poor access
Solution Approach 1:
The patent eliminates the impregnation process entirely by designing the slot wall insulation with integrated mechanical retention features. The tooth-shaped protrusions directly secure the electrical conductors through physical interlocking, removing the need for additional impregnation materials and the associated quality control issues.
Solution Approach 2:
The slot wall insulation structure provides its own mechanical retention function through the tooth-shaped configurations that directly engage with the electrical conductors. This self-service mechanism eliminates the need for separate impregnation processes and provides reliable mechanical fixation.
3Temperature
If slot wall insulation wall thickness is reduced to improve cooling, then heat dissipation is improved, but mechanical strength and insulation effectiveness deteriorate
Solution Approach 1:
The patent uses composite plastic materials with enhanced thermal conductivity to achieve effective heat dissipation in thinner insulation walls. The filler particles create thermal conduction pathways that compensate for the reduced wall thickness, maintaining cooling effectiveness while preserving mechanical strength.
Solution Approach 2:
The patent optimizes the material parameters by selecting plastics with specific thermal conductivity properties and adjusting filler content to enable thinner wall designs that maintain both mechanical strength and thermal performance.
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 configuration enhances heat dissipation by allowing direct cooling of electrical conductors, enabling thinner insulation walls and reduced manufacturing costs, while maintaining or improving power output.
Implementation Method 1
the thermal conductivity of slot insulations is a power-limiting factor for electric motors. In traditional electric motor cooling architectures, usually the lost heat is discharged to the outside from the electrical conductors by the impregnation and insulation materials via the stator laminated core.
Implementation Method 2
an insulation material is deposited on the stator slots in an injection molding process, enclosing them
Data Source
AI summary
An electric motor including a stator body with a stator laminated core and a stator slot, wherein the stator slot has a slot wall with a slot wall insulation for electrical insulation, as well as at least one electrical conductor which is received by the stator slot, the slot wall insulation having a tooth-shaped configuration.