Injection-Molded Motor Stator Fastening for Thermal Stress
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Solution Overview
Problem
The existing stator fastening portions in washing machines are prone to breakage due to thermal stress caused by motor operation, leading to structural weaknesses and potential failure.
Innovation Solution
A reinforced stator fastening structure is achieved through injection molding of the stator core, insulator, and fastening portions as a single unit, with vertically arranged ribs and symmetric design to distribute thermal stress evenly, and strategically placed pass-through holes and gate portions to enhance structural integrity and thermal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the stator is fastened using conventional separate fastening portions, then the manufacturing process is simpler, but the fastening portions are prone to breakage due to thermal stress
Solution Approach 1:
The patent combines the fastening portions with the insulator into a single integrated component formed by injection molding. The fastening portions are formed as protrusions that extend from the insulator body, eliminating the need for separate fastening parts. This integration strengthens the fastening structure against thermal stress while simplifying the overall assembly by reducing the number of components.
Solution Approach 2:
The patent uses a composite structure where the insulator and fastening portions are formed as a single integrated component through injection molding. This creates a unified structure that combines the insulating function with the fastening function, improving durability under thermal stress while maintaining manufacturing efficiency.
2Stability of the object's composition
If the stator core and insulator are assembled separately, then the manufacturing process is simpler, but the thermal stress distribution is uneven causing breakage
Solution Approach 1:
The patent integrates the fastening portions directly into the insulator body through injection molding, creating a unified structure. This integration ensures that thermal stress is distributed evenly across the entire insulator-f fastening portion assembly, eliminating the interface between separate components that would otherwise create stress concentration points.
3Strength
If reinforcement ribs are added to the fastening portions, then the structural strength is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent incorporates reinforcement ribs as integral features of the fastening portions during the injection molding process. The ribs protrude from the fastening portion surfaces and are formed simultaneously with the main body, providing enhanced structural strength without requiring additional manufacturing steps or separate components.
Data Source
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AI summary
The present invention relates to a stator of an electric motor and a washing machine having the same, wherein the stator includes a stator core of a stack of bases each with a plurality of poles, an insulator having an upper insulator and a lower insulator fastened to the stator core, a plurality of fastening portions each having a fastening hole for fastening the stator, and a plurality of connection portions each having a plurality of vertical ribs for connecting the insulator to each of the fastening portions, wherein the insulator, the fastening portions, and the connection portions are injection molded as one unit, with the stator core inserted thereto.