Gear Box Terminal Integration via Segmented Support
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Solution Overview
Problem
Conventional gear boxes with integrated metal terminals via insert molding face instability due to limited support points for the terminal, leading to degraded quality and molding performance.
Innovation Solution
A gear box design with a resin gear box body that includes a storage portion for the output shaft, a motor insertion portion, and a connector connection portion, where the terminal is supported at two points by a motor feeding portion and a fixing tab, allowing for stable integration through a specialized mold configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the terminal is held in the mold during insert molding, then the terminal can be integrated with the gear box body, but the terminal is unstably held due to limited support points
Solution Approach 1:
The terminal is divided into multiple support points (motor feeding portion and fixing tab) that are separately positioned and supported within the mold during insert molding, allowing stable holding at multiple locations rather than a single point
Solution Approach 2:
The terminal is pre-positioned and held in the mold at specific locations (motor insertion portion and connector connection portion) before the resin injection process begins, ensuring proper positioning and stable support throughout the molding operation
Data Source
AI summary
A gear box includes a gear box body, and a terminal which is integrated with the gear box body. The gear box body includes a storage portion which stores a gear, a motor insertion portion, recessed in an attachment surface of a motor, and a connector connection portion on the same side as the motor insertion portion with respect to a rotation center of the gear and is open in a direction different from the motor insertion portion. The terminal includes the connector terminal which is exposed to the inside of the connector connection portion, a motor feeding portion which is exposed to the inside of the motor insertion portion, a connecting portion which is in the gear box body and connects the connector terminal and the motor feeding portion, and a fixing tab extending from the connecting portion and exposed to the inside of the motor insertion portion.