Electric Motor Bus Bar With Through Holes For Resin Flow
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Solution Overview
Problem
Conventional bus bar fabrication methods using resin injection often result in inadequate resin filling, leading to reduced strength and insulation quality between wiring members in electric motors.
Innovation Solution
The bus bar design incorporates through holes in the wiring members to facilitate resin injection molding, ensuring effective resin filling between the members, thereby enhancing insulation and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the bus bar is fabricated by integrally molding the plurality of wiring members with the resin, then the manufacturing process is simplified, but the resin injected into the die has been hardly injected into the wiring members, thereby possibly degrading the strength of the bus bar or insulation between the wiring members
Solution Approach 1:
The wiring members are designed with through-holes that create porous pathways, allowing the resin to penetrate effectively through and between the wiring members during injection molding. This ensures proper resin filling while maintaining the integral molding process, thereby resolving the contradiction between manufacturing simplicity and product quality.
2Quantity of substance
If the wiring members are arranged with intervals in the axial direction, then the resin can be injected between them, but the resin has been hardly injected into the wiring members without through holes
Solution Approach 1:
By incorporating through-holes in the wiring members, the design creates porous structures that facilitate resin penetration. This ensures adequate resin filling between and within the wiring members while maintaining proper insulation and structural integrity, thus resolving the contradiction between resin quantity and reliability.
3Object-affected harmful factors
If the resin portion covers the surroundings of the wiring members by injection molding, then the insulation is provided, but inadequate resin filling leads to reduced insulation quality
Solution Approach 1:
The through-holes in the wiring members create porous pathways that guide resin flow, ensuring complete and uniform resin filling around all wiring members. This maintains high insulation quality while achieving precise and complete resin coverage, resolving the contradiction between insulation performance and manufacturing precision.
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 approach allows for improved resin filling, enhancing the insulation and mechanical strength of the bus bar, which is critical for reliable operation, especially in high-current applications like power steering systems.
Implementation Method 1
a resin portion for covering the surroundings of the two or more wiring members by injection molding
Data Source
AI summary
A bus bar secured to a stator in an electric motor in a preferred embodiment according to the invention includes four wiring boards, which are arranged perpendicularly to a center axis at intervals in a direction toward the center axis, and a resin portion for covering the surroundings of the four wiring boards by injection molding. Resin passing holes, through which a resin flows when the resin portion is molded, are formed at each of the wiring boards. When the bus bar is molded, the resin is injected into a resin molding die in a state in which the four wiring boards are supported by supporting pins disposed inside of the die. The resin flows to and fro between a space defined between the die and the wiring board and a space defined between the adjacent wiring boards.