Insulator Ribs Suppress Resin Shrinkage in Coil Winding
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Solution Overview
Problem
The integration of a resin insulator with a divided iron core in rotary electric machines leads to reduced molding accuracy and potential bulging of coil terminal wires due to resin shrinkage and the formation of recesses in the wiring member, which affects the positioning and stability of the terminal wires.
Innovation Solution
The design incorporates a wiring member with recesses on its groove bottom surface and ribs between adjacent recesses to support the coil terminal wires, reducing resin shrinkage and preventing the wires from entering the recesses, thus maintaining accurate alignment and preventing bulging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the insulator is resin molded integrally with the divided iron core, then the insulator can cover the yoke portion and provide structural support, but the hollow portion molding die cannot be pulled out to the yoke portion side, causing large resin shrinkage and reduced molding accuracy
Solution Approach 1:
The bottom surface of the accommodating groove is segmented into multiple recesses arranged in the circumferential direction. This segmentation allows the hollow portion molding die to form multiple separate cavities that can be filled with resin, reducing overall shrinkage while maintaining the integrated structure between the insulator and divided iron core.
Solution Approach 2:
The recesses are pre-formed in the bottom surface of the accommodating groove before the final molding process. This preliminary action creates space that compensates for resin shrinkage during molding, ensuring the molding accuracy is maintained while keeping the insulator integrally molded with the divided iron core.
2Manufacturing precision
If the hollow portion molding die is pulled outwardly in the radial direction to form hollow portions, then resin shrinkage is reduced, but recesses are formed in the bottom surface of the accommodating groove causing coil terminal wires to enter and bulge outwardly
Solution Approach 1:
Ribs are introduced as intermediary structures between the adjacent recesses in the bottom surface of the accommodating groove. These ribs act as barriers that prevent coil terminal wires from entering the recesses while allowing the hollow portions to be formed for reducing resin shrinkage. The ribs maintain the proper alignment and shape of the accommodating groove.
3Manufacturing precision
If multiple recesses are formed in the groove bottom surface, then resin shrinkage is suppressed and molding accuracy is improved, but the coil terminal wire may enter the recess and cause bulging
Solution Approach 1:
Ribs are positioned between the adjacent recesses to serve as protective barriers. These ribs prevent the coil terminal wire from entering the recesses while allowing the hollow portions to be formed for reducing resin shrinkage. This ensures both molding accuracy and reliable positioning of the coil terminal wire are achieved simultaneously.
Data Source
AI summary
An insulator of a coil winding component constituting part of a rotary electric machine is resin molded integrally with a divided iron core. A first accommodating groove in which a coil terminal wire can be arranged is formed on an outer end surface of a wiring member of the insulator. A plurality of recesses are formed in a circumferential direction of a stator core on a groove bottom surface of the first accommodating groove. Further, a rib, which supports the coil terminal wire that is arranged in the first accommodating groove, is disposed between the mutually adjacent recesses.