Annular Stator Connector for Compact Motor Design
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Solution Overview
Problem
The existing connectors for stators in permanent magnet brushless direct-current motors occupy significant axial space, limiting the compactness and miniaturization of the motor.
Innovation Solution
A compact connector design featuring an annular carrier structure made of electrically insulating plastic overmolded conducting members with arc-shaped projections for connecting coils, allowing for reduced axial height and efficient phase winding formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a conventional connector structure is used to connect stator coils, then reliable electrical connectivity is achieved, but the axial length of the motor increases
Solution Approach 1:
The connector merges multiple functions into a single integrated structure: the insulating body houses conducting members for electrical connection, while simultaneously providing mechanical support and positioning for the stator coils. This consolidation eliminates the need for separate connector components, reducing axial length while maintaining connectivity reliability
Solution Approach 2:
The conducting members are nested within the insulating body structure, with the insulating material surrounding and protecting the conductive elements. This nested arrangement allows the connector to maintain compact axial dimensions while ensuring both electrical connectivity and insulation are provided by the same integrated component
2Length of moving object
If the connector height is reduced to minimize axial space, then compactness is improved, but manufacturing complexity increases
Solution Approach 1:
The connector uses composite construction combining insulating plastic material with embedded conducting members. This composite approach allows the insulating body to be molded with integrated conducting elements, achieving compact dimensions through material integration rather than complex mechanical assembly of multiple parts
Solution Approach 2:
The insulating body serves multiple functions simultaneously: providing electrical insulation, mechanically supporting the conducting members, positioning the stator coils during assembly, and structurally reinforcing the connector. This multi-functionality reduces the need for additional components, simplifying manufacturing despite the compact form factor
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
The solution reduces the axial length of the motor by providing a compact connector that effectively connects coils, enabling a smaller and lighter motor design while maintaining electrical insulation and connectivity.
Implementation Method 1
manufactured with an electrically insulating plastic material overmolded on a group of N conducting members which are separated and electrically insulated from one another by means of the plastic material
Implementation Method 2
the first projections being adapted to be connected, in particular by welding or soldering, to terminals or ends of the coils of the stator
Implementation Method 3
the first projections being adapted to be connected, in particular by welding or soldering, to terminals or ends of the coils of the stator
Data Source
AI summary
A stator connector has an annular carrier structure adapted to be superposed on and fixed to the central annular portion of the stator and manufactured from an electrically insulating plastic overmolded onto a group of N conducting members which are separated from each other and electrically insulated by said plastic and having a generally arcuate shape. The conducting members have respective first projections extending out of the annular carrier structure. These first projections are adapted to be connected, in particular by soldering or welding, to terminals or ends of coils of the stator. Each conducting member further has at least one additional connection projection extending out of the annular carrier structure to form phase terminals for the stator.