Elastic Plug Sealing for Electric Motor Lead Wires
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Solution Overview
Problem
Conventional electric motor manufacturing methods face sealant leakage issues through the lead wire drawing portion, which compromises the sealing effect and can lead to deteriorated thermal and electric insulation properties.
Innovation Solution
An electric motor assembly with a partition wall and plugs made of highly elastic materials, where the plugs are tapered and fitted into through-holes to prevent sealant leakage by pressing their outer surfaces against the inner surfaces, creating a tight seal around the lead-wire insertion holes, and a manufacturing method that involves injecting a sealant to press the plugs outwardly and close the clearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a seal member (grommet) is used to seal the through-hole for lead wire drawing, then the lead wire can be drawn through, but the sealant may leak through the lead-wire insertion hole or gap between the seal member and the through-hole due to injection pressure
Solution Approach 1:
The partition wall is segmented into multiple sections with through-holes positioned at different locations and orientations. Each through-hole is sealed by a separate plug, allowing the lead wire drawing function to be maintained while preventing sealant leakage through multiple discrete sealing points.
Solution Approach 2:
A plug made of highly elastic material serves as an intermediary element between the sealant space and the non-sealant space. This plug mediates the conflict between allowing lead wire passage and preventing sealant leakage by providing a flexible sealing interface that deforms under injection pressure to close the through-hole.
2Reliability
If sealant is injected at certain pressure to seal the stator, then the sealing effect is enhanced, but the sealant may leak through the lead wire drawing portion
Solution Approach 1:
The plugs are pre-installed in the through-holes of the partition wall before sealant injection. These plugs are made of highly elastic material that anticipates the incoming injection pressure and is designed to deform outward to close the through-holes, thereby preventing sealant leakage before it can occur.
Solution Approach 2:
The plug material is selected with highly elastic properties that allow it to change its physical state under injection pressure. When sealant is injected, the pressure causes the plug to deform and change shape, closing the through-hole and preventing leakage while maintaining the sealing effect.
3Reliability
If the plug is made of highly elastic material to prevent leakage, then the sealing effect is improved, but the plug must be pressed outwardly by injection pressure to close the clearance
Solution Approach 1:
The plug is made of highly elastic material that functions as a flexible sealing element. This flexible plug can deform under injection pressure to close the through-hole, preventing sealant leakage while accommodating the pressure requirements of the sealing process.
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
Effectively prevents sealant leakage through the lead wire drawing portion, enhancing the sealing effect and maintaining the electric insulation properties of the motor.
Implementation Method 1
The plug is made of a material having elasticity higher than elasticity of a material composing the casing
Implementation Method 2
pressing their outer surfaces against the inner surfaces, creating a tight seal around the lead-wire insertion holes
Implementation Method 3
The sealant 10 is composed of, for example, synthetic resin material such as unsaturated polyester resin having an electric insulation property and a thermal conductivity
Implementation Method 4
synthetic resin material having an electric insulation property and a thermal conductivity
Data Source
AI summary
Provided are, an electric motor assembly capable of preventing a sealant from leakage through a lead-wire drawing portion, and an electric motor manufacturing method with use of the electric motor assembly. The electric motor assembly includes a rotor, a stator, a casing, a partition wall with through-holes, plugs made of a highly elastic material and including a tapered outer peripheral surface to be fitted into the through-holes, and lead wires connected to the stator. The plugs surround lead-wire insertion holes. A sealant is injected into the casing in a state that the lead wires are drawn through the lead-wire insertion holes. The injection pressure presses the plugs outwardly to bring the outer peripheral surfaces of the plugs into close contact with the inner peripheral surface surrounding the through-holes and elastically deforms the plugs in a diameter-reduction direction to cause the plugs to close the lead-wire insertion holes.