Intermediate Insulating Part for External Rotor Motor Sealing
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Solution Overview
Problem
Existing electric motors with external rotor designs face challenges in maintaining air and leakage paths, achieving reliable sealing, and efficiently dissipating heat, requiring multiple components that complicate assembly and increase costs.
Innovation Solution
An intermediate insulating part made of electrically insulating plastic with a hard support component and a soft sealing component, connected by material fusion or form fit, which includes a pressing element to securely attach heat-generating components to a cooling surface, thereby fulfilling multiple functions such as sealing, heat transfer, and maintaining air paths with a single component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate components (sealing elements, clamps, insulating parts) are used to fulfill different functions, then the required sealing, heat dissipation, and air path maintenance can be achieved, but the device complexity and assembly difficulty increase
Solution Approach 1:
The patent combines multiple previously separate components (sealing element, pressing element, intermediate insulating part) into a single integrated intermediate insulating part made of thermoplastic elastomer. This merging reduces the number of components while maintaining sealing, heat dissipation, and air path maintenance functions, directly resolving the contradiction between reliability and device complexity
Solution Approach 2:
The intermediate insulating part is designed to perform multiple functions simultaneously: electrical insulation, sealing (through soft sealing lip), heat dissipation (through thermal contact with cooling surface), and maintaining air paths. This multi-functionality eliminates the need for separate components for each function, reducing overall device complexity while ensuring reliable performance
2Reliability
If multiple separate components are used for sealing and heat dissipation, then the required functions can be fulfilled, but the manufacturing and assembly costs increase
Solution Approach 1:
The patent merges the sealing element and pressing element into the intermediate insulating part as an integrated component. This reduces the number of manufacturing steps and assembly operations, lowering both manufacturing and assembly costs while ensuring reliable heat dissipation through the integrated pressing element that maintains thermal contact
3Reliability
If multiple components are assembled together, then the required functions can be achieved, but the risk of faulty assembly increases
Solution Approach 1:
By integrating the sealing element and pressing element into a single intermediate insulating part, the patent eliminates multiple assembly steps and potential misalignment issues between separate components. The integrated design ensures proper positioning and function of sealing and pressing elements, reducing assembly errors while maintaining reliable sealing action
4Strength
If a hard component is used for the intermediate insulating part, then structural stability and strength are provided, but sealing action is insufficient
Solution Approach 1:
The patent uses thermoplastic elastomer as the material for the intermediate insulating part, which combines the properties of hard components (structural stability, strength, electrical insulation) with the properties of soft components (elasticity, sealing capability). This composite material approach allows a single component to provide both structural support and effective sealing action through its inherent material properties
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
This multi-functional component simplifies assembly, reduces manufacturing and assembly costs, ensures reliable sealing and heat dissipation, and minimizes the risk of faulty assembly while maintaining air and leakage paths, providing an optimal sealing action and efficient heat transfer.
Implementation Method 1
The intermediate insulating part (1) is comprised of a hard component and a soft sealing part (14), which is joined by material fusion and/or form fit to the hard component
Implementation Method 2
the intermediate insulating part has the at least one pressing element with which the heating component is pressed against the cooling surface. In this way, the heat can be properly discharged from this component to the cooling surface
Data Source
AI summary
The invention relates to an electric motor having a stator and an electronics compartment which receives electric/electronic structural parts. Said electric motor is accommodated in an electronics housing and can be closed by a housing cover. In order to maintain leakage paths and/or air paths between the housing cover and the electric/electronic structural parts, the electric motor has an intermediate insulating part (1) which is made of an electrically insulating plastic and has a supporting part as hard component and at least one soft component as sealing part (14, 25). The soft component is connected cohesively and/or by positive engagement to the hard component. The intermediate insulating part (1) has at least one pressing element (33) by which at least one heat-generating structural part is pressed against a cooling surface. The intermediate insulating part (1) has a hood-shaped support which is made of a hard, electrically insulating plastic. At least one sealing part (14, 25) made of a soft component is connected to said support. Moreover, the intermediate insulating part (1) has at least one pressing element (33).