Flat-Wire Motor Busbar Molding for Compact Insulation Safety
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Solution Overview
Problem
The exposure of solder joints in flat wire motors reduces insulation safety, leading to a large volume and difficulty in miniaturization due to the need for increased insulation safety distances.
Innovation Solution
The implementation of a motor design that includes a stator core with a multiphase winding structure, where each phase has lead-out ends connected to lead-out wires, and an injection molding structure that fastens busbars to maintain insulation safety and reduce volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solder joints are exposed outside the injection molding part for connection, then electrical connection is implemented, but insulation safety is reduced and motor volume increases
Solution Approach 1:
The injection molding part is designed to wrap and embed the lead-out copper bars, with the solder joints positioned within the molded structure rather than exposed externally. This nesting approach allows the insulation material to surround the conductive elements, maintaining insulation safety while compacting the overall motor volume.
Solution Approach 2:
The design transitions from exposing solder joints on the external surface to positioning them within the three-dimensional structure of the injection molding part. By utilizing the internal space and repositioning elements in different spatial dimensions, the patent achieves both insulation safety and volume reduction.
2Reliability
If lead-out copper bars are spaced from each other and form an overall structure through injection molding, then insulation is strengthened and fastening is improved, but the motor volume increases to meet insulation safety distance requirements
Solution Approach 1:
The injection molding part combines multiple functions into a single integrated structure: it provides insulation between lead-out copper bars, mechanically fastens them together, and positions them within the stator assembly. This merging eliminates the need for separate insulation components and reduces overall motor volume while maintaining insulation safety.
Solution Approach 2:
The injection molding process allows for precise control of material properties and dimensional parameters. By optimizing the thickness, material composition, and geometric configuration of the molded part, the design achieves adequate insulation safety distances within a compact volume, rather than requiring uniform large spacing.
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 design enhances insulation safety, reduces the motor's volume, and facilitates miniaturization by maintaining the required insulation safety distances while minimizing physical size.
Implementation Method 1
the U-phase lead-out copper bar, the V-phase lead-out copper bar, and the W-phase lead-out copper bar may be spaced from each other and form an overall structure through injection molding of an injection molding part
Data Source
AI summary
This application provides a motor, a powertrain, and a vehicle. The motor includes a stator core and a winding structure wound around the stator core, and further includes a first injection molding structure which includes a first injection molding part and a plurality of first busbars. The first electrical connector of each first busbar is correspondingly connected to a first lead-out end of each phase of the winding structure. The first injection molding part wraps the first main body part of the first busbar. An insulation cover is disposed on the first injection molding structure, the insulation cover covers the exposed first electrical connector and the exposed first lead-out end.