Motor Busbar Holder Structure for Lower Insulation Material Use
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Solution Overview
Problem
The existing busbar units for motors face challenges in simplifying their structure and reducing costs while maintaining insulation performance, as the use of insulating materials increases weight and manufacturing time, and it is difficult to minimize the size and amount of insulating material due to the circular shape of the holder's inner surface.
Innovation Solution
The busbar unit features a holder with a noncircular inner surface having crest and trough portions, allowing for reduced insulation material usage and weight, with a cover layer and protrusion portions that match the holder's shape, and a support portion with stepped sections to increase the creeping distance between terminals, enhancing stability and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating material is applied to cover the first terminal portion to ensure insulation between terminals, then insulation performance is improved, but weight increases, costs increase, and curing time increases
Solution Approach 1:
The patent extracts the insulating function from a separate material layer and integrates it into the holder structure itself. The holder includes protrusion portions that extend between adjacent terminals to provide insulation, eliminating the need for additional insulating material covering the terminal portions.
Solution Approach 2:
The holder is designed to perform multiple functions: mechanical support of terminals and integrated electrical insulation. The protrusion portions of the holder simultaneously provide structural support and insulation barriers between terminals, combining two functions into a single component.
2Reliability
If insulating material is applied to cover the first terminal portion, then insulation performance is improved, but manufacturing time increases due to longer curing time
Solution Approach 1:
The patent removes the separate insulating material application step by extracting the insulating function and embedding it in the holder's protrusion portions, eliminating the curing process entirely.
Solution Approach 2:
The insulating function is built into the holder structure before terminal assembly. The protrusion portions are pre-formed as part of the holder, providing insulation readiness before terminals are installed, eliminating post-assembly insulating material application and curing time.
3Device complexity
If the inner circumferential surface of the holder is formed in a circular shape, then structural simplicity is maintained, but it is difficult to reduce the size and amount of insulating material
Solution Approach 1:
The holder's inner circumferential surface features asymmetric protrusion portions that extend between adjacent terminals. This asymmetric design strategically places material only where insulation is needed, rather than using a uniform circular shape that would require more material.
Solution Approach 2:
The holder structure implements local quality by adding protrusion portions only in specific locations between terminals where insulation is required, rather than uniformly thickening the entire holder structure. This localized approach reduces overall material usage while maintaining necessary insulation performance.
4Ease of manufacture
If the holder structure is simplified to reduce costs, then manufacturing cost decreases, but insulation performance may be compromised
Solution Approach 1:
The holder is designed as a multi-functional component that simultaneously provides mechanical support and electrical insulation through its protrusion portions. This eliminates the need for separate insulating materials, reducing overall component count and manufacturing cost while maintaining insulation performance.
Solution Approach 2:
The patent merges the support function and insulation function into a single holder structure. The protrusion portions integrate what would traditionally be separate components (holder and insulating material), simplifying the manufacturing process and reducing costs while ensuring insulation performance.
Data Source
AI summary
The present disclosure relates to a busbar unit for a motor, the busbar unit including: a holder having an inner circumferential surface on which crest portions and trough portions connected to the crest portions are formed; and a terminal coupled to the holder and including first terminal portions disposed on the crest portions, such that it is possible to obtain an advantageous effect of simplifying a structure and reducing costs.