Alternating Insulating Holders for Compact Motor Power Distribution
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Solution Overview
Problem
In motor power distribution apparatuses, the molded resin and insulating holders may not completely cohere during the insertion molding process, leading to gaps and requiring an increased height of the insulating holder walls for adequate creepage insulation, which complicates the design and increases the size of the power distribution system.
Innovation Solution
The use of first and second insulating holders, disposed alternately without contacting each other, where the first holders retain every other bus bar and the second holders retain the remaining bus bars, ensuring sufficient creepage insulation without raising the height of the insulating holder walls by covering non-contiguous bus bars with molded resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the height of the insulating holder wall is raised to ensure creepage insulation, then the insulating capability is improved, but the size of the power distribution system increases
Solution Approach 1:
The insulating holders are segmented into first and second types that are alternately arranged. The first insulating holders retain every other bus bar, while the second insulating holders retain the remaining bus bars. This segmentation allows each holder to have a reduced wall height while collectively providing sufficient creepage insulation across all bus bars.
Solution Approach 2:
Instead of increasing insulation in the vertical dimension (wall height), the solution transitions to the horizontal dimension by alternately arranging first and second insulating holders. This dimensional shift maintains creepage insulation effectiveness while reducing the vertical size of the power distribution system.
2Reliability
If the height of the insulating holder wall is raised to ensure creepage insulation, then the insulating capability is improved, but the design complexity increases
Solution Approach 1:
The insulating holders are divided into first and second types with alternating arrangement. This segmentation simplifies the design of individual holders (reduced wall height) while maintaining overall insulating capability through the alternating pattern, avoiding the complexity of designing and manufacturing taller single-type holders.
Solution Approach 2:
Instead of using uniform tall insulating holders for all bus bars, the invention inverts the approach by using alternating short holders (first and second types) that collectively achieve the required insulation. This inversion simplifies individual component design while maintaining system-level performance.
3Manufacturing precision
If gaps form between insulating holders and molded resin, then manufacturing variability increases, but maintaining adequate creepage insulation becomes more difficult
Solution Approach 1:
The alternating arrangement of first and second insulating holders creates multiple discrete insulation points along the bus bars. This segmentation ensures that even if gaps form at some locations, the alternating pattern provides multiple other locations where creepage insulation is maintained, compensating for manufacturing variability.
Solution Approach 2:
The alternating insulating holder configuration provides built-in redundancy that cushions against the harmful effect of gaps. By distributing insulation functions across multiple alternating holders, the system anticipates and compensates for potential bonding failures, ensuring creepage insulation is maintained despite manufacturing variability.
Data Source
AI summary
A motor power distribution apparatus includes first insulating holders and second insulating holders. The first insulating holders are disposed to retain every other one of a plurality of stacked power distribution members that are unified by insert molding. The second insulating holders are disposed to retain power distribution members other than the power distribution members retained by the first insulating holders.