Molded Enameled Copper Wire Contacts for Compact Motor Windings
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Solution Overview
Problem
Existing methods for electrical contacting of enameled copper wires in electric motors, generators, sensors, or electromagnets are complex, space-consuming, and require additional processes like soldering or insulation stripping.
Innovation Solution
A method involving forming wire ends into electrical contacts, positioning these contacts in a molding process where the molding compound surrounds the components and wire ends, and establishing contact with a second component, thereby simplifying and securing the electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact plugs or soldering or welding are used for electrical contacting, then reliable electrical connection is achieved, but the process becomes complex and space-consuming
Solution Approach 1:
The patent combines multiple functions into the molding compound: electrical insulation, mechanical support, heat dissipation, and structural positioning. The molding compound integrates these functions that were previously performed by separate components (insulation layers, mounting structures, heat sinks), thereby simplifying the overall device structure while maintaining reliable electrical connections.
Solution Approach 2:
The molding compound serves multiple purposes simultaneously: it provides electrical insulation around the enameled copper wire, mechanically supports the electrical contact, dissipates heat generated during operation, and positions components within the assembly. This multi-functionality reduces the number of separate components needed and simplifies the contacting process.
2Reliability
If contact plugs or soldering or welding are used for electrical contacting, then reliable electrical connection is achieved, but additional processes and space are required
Solution Approach 1:
The patent merges the electrical contact structure with the molding compound, eliminating the need for separate contact plugs, soldering joints, or welding assemblies. The molding compound itself becomes the structural element that holds and protects the electrical contact, significantly reducing the volume required for the contacting structure.
Solution Approach 2:
The invention extracts the essential function of electrical contacting from complex assemblies (contact plugs, soldering equipment, welding tools) and implements it directly through the molded structure. The enameled copper wire with formed electrical contact is positioned and secured within the molding compound, removing unnecessary components and reducing overall volume.
3Reliability
If traditional contacting methods are used, then electrical connection is established, but heat dissipation is inefficient
Solution Approach 1:
The molding compound is designed to simultaneously provide electrical insulation and heat dissipation. By incorporating thermally conductive materials into the molding compound or designing it with thermal pathways, the structure that provides electrical stability also efficiently dissipates heat, converting a single-component solution into a multi-functional system that addresses both reliability and energy loss.
4Ease of manufacture
If insulation stripping is performed, then electrical contact is prepared, but the process becomes more complex and less safe
Solution Approach 1:
The enameled copper wire is designed with pre-formed electrical contact geometry that exposes the conductive material in a controlled manner during the molding process. The forming step creates the electrical contact shape while the molding process simultaneously removes or exposes the enamel insulation where needed, eliminating the need for separate insulation stripping operations and improving process safety.
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 method simplifies the contacting process, reduces space requirements, allows for efficient heat dissipation, and eliminates the need for insulation stripping, making it safer and more efficient.
Implementation Method 1
heat can be efficiently dissipated via the molding compound formed in the molding process
Implementation Method 2
the winding wire is preferentially heated during the forming process, which is accompanied by a removal of the insulation of the wire
Data Source
AI summary
A method of electrically contacting at least one enameled copper wire, which forms a winding carried by a first component, with a second component of an electric motor, generator, sensor or electromagnet. The method includes forming at least one wire end of the at least one enameled copper wire into an electrical contact, positioning the electrical contact in a molding process, a molding compound formed in the molding process at least partially surrounds the first component and the at least one wire end, and contacting the electrical contact with the second component.