Fluid Circulator Motor Sealing for Aluminum-Copper Connections
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Solution Overview
Problem
Centrifugal electric pumps, or circulators, face oxidation and redox issues at the electrical connection between aluminum wire windings and copper power supply terminals, leading to deterioration and reduced service life in aggressive environments.
Innovation Solution
A fluid circulator with an aluminum or aluminum alloy electrical winding and a protective over-molding of plastic material to seal the electrical connection, ensuring stable and durable contact by eliminating exposure to oxidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If aluminum wire is used for electrical windings to reduce weight and cost, then weight and manufacturing cost are reduced, but oxidation and redox issues occur at the electrical connection with copper terminals
Solution Approach 1:
A transition piece made of aluminum alloy is introduced as an intermediary component between the aluminum winding and copper terminal. This transition piece features an aluminum end that connects to the aluminum winding and a copper end that connects to the copper terminal, thereby eliminating direct contact between dissimilar metals and preventing oxidation and redox issues at the junction.
2Ease of manufacture
If aluminum wire is used for electrical windings, then manufacturing cost is reduced, but deterioration occurs at the electrical connection in aggressive environments
Solution Approach 1:
The transition piece serves as a mediator that protects the electrical connection by preventing direct exposure of the aluminum-copper junction to aggressive environmental conditions. The sealed enclosure further protects the transition piece and connection area from moisture and corrosive agents, ensuring long-term durability while maintaining the cost benefits of aluminum windings.
3Reliability
If traditional sealing methods are used for electrical connections, then protection is provided, but complexity of the device increases
Solution Approach 1:
The transition piece and sealing structure are merged into a single integrated component. The transition piece itself is designed with sealing features that eliminate the need for separate sealing elements, thereby providing effective protection against moisture and contaminants while minimizing device complexity and maintaining ease of assembly.
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 provides a stable electrical contact over time, enhancing the circulator's durability and service life, even in harsh conditions.
Implementation Method 1
oxidation and redox problem of the electrical connection between aluminium wire of the winding and power supply terminal
Implementation Method 2
oxidation and redox problem of the electrical connection between aluminium wire of the winding and power supply terminal
Data Source
AI summary
An electric motor for a fluid circulator. The electric motor includes a plastic portion and a stator with an electrical winding made of aluminum or aluminum alloys. The electric motor includes a connecting element made of a material that is not aluminum or aluminum alloys. The connecting element is in contact with the electrical winding of the stator forming an electrical connection between the connecting element and the electrical winding. The electric motor also includes an overmolding of plastic material integral with the plastic portion. The overmolding of plastic material sealingly encloses the at least one electrical connection.