Integrally Molded Motor Mount for Vibration Isolation Retention
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Solution Overview
Problem
Mold motors installed on outdoor units of air conditioners with vibration-proof rubber interposed are prone to falling off due to extreme weather conditions such as typhoons or earthquakes, as the vibration-proof rubber is retrofitted to the mold resin and not securely integrated during the molding process.
Innovation Solution
The mold motor design includes a stator, rotor, and mold resin with an elastic body and hard members, such as tubular members made of metal, integrated by molding to secure the vibration-proof rubber and tubular members to the mold resin, preventing deformation and ensuring secure attachment to the installation object.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If vibration-proof rubber is retrofitted to the mold resin after stator molding, then noise reduction is achieved through vibration absorption, but the attachment reliability deteriorates under extreme conditions such as typhoons or earthquakes
Solution Approach 1:
The vibration-proof rubber is pre-positioned within the mold cavity before the mold resin is injected. The molding process then integrates the rubber with the stator in a single operation, creating a preliminary bonded state that prevents detachment under extreme conditions while maintaining vibration absorption capabilities
Solution Approach 2:
The vibration-proof rubber and mold resin are merged into a single integrated structure through the molding process. The rubber and resin form a composite attachment member where both materials work together as one unit, eliminating the interface between separate components and preventing detachment
2Ease of manufacture
If vibration-proof rubber is attached to the leg of the mold resin after molding, then ease of installation is improved, but manufacturing precision deteriorates due to potential deformation and misalignment
Solution Approach 1:
The vibration-proof rubber is pre-positioned in the exact desired location within the mold cavity before resin injection. The molding process then fixes the rubber in this precise position, eliminating subsequent alignment operations and ensuring high positioning accuracy while maintaining installation simplicity
Solution Approach 2:
The positioning and attachment operations are merged into the single molding process. The rubber's final position is determined during molding itself, combining the precision of mold-based positioning with the simplicity of integral formation, eliminating separate alignment steps
3Reliability
If vibration-proof rubber is integrally molded with the stator, then attachment reliability is improved under extreme conditions, but device complexity increases due to additional molding considerations
Solution Approach 1:
The molding of the stator and the attachment of the vibration-proof rubber are merged into a single integrated molding operation. This eliminates the need for separate attachment steps and reduces overall process complexity despite the enhanced reliability achieved through integral formation
Solution Approach 2:
The molding process is designed to perform multiple functions simultaneously: forming the stator structure, positioning the vibration-proof rubber, and bonding them together. This multi-functionality reduces the number of separate operations needed, offsetting the increased complexity of the integrated process with overall simplification
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 configuration effectively prevents the mold motor from falling off during strong winds or earthquakes while maintaining noise reduction through vibration absorption, ensuring stable attachment and reduced vibration transmission.
Implementation Method 1
an elastic body attached to an installation object in which the mold motor is installed
Implementation Method 2
a rotor including a rotation shaft and rotating by a magnetic force of the stator
Data Source
Figure 1
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AI summary
A stator, a rotor including a rotating shaft and rotating by a magnetic force of the stator, a mold resin covering at least a part of the stator, a vibration-proof rubber that is an elastic body attached to an installation object on which the mold motor is installed, and one or more hard members disposed around the vibration-proof rubber and harder than the vibration-proof rubber are included, and the vibration-proof rubber and the hard members are fixed to the mold resin by integral molding.