Motor Bus Bar Attachment for Heat- and Vibration-Stable Stators
Solution Overview
Problem
Current electric motor stator assemblies face challenges in securely attaching bus bar assemblies and printed circuit board assemblies, leading to potential electrical disconnects and mechanical instability, particularly in high-temperature and high-vibration environments.
Innovation Solution
The use of a non-conductive body with radially protruding arms or receptacles, made from thermoplastic materials that melt and bond upon cooling, to securely attach the bus bar assembly to the insulator, and a method involving ultrasonic welding, thermal pressing, or heat staking to integrate the bus bar and printed circuit board assemblies with the stator, ensuring robust electrical connections and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mechanical fastening methods are used to attach bus bar assemblies and printed circuit board assemblies to the stator, then the assembly process is simple and straightforward, but the reliability of electrical connections deteriorates in high-temperature and high-vibration environments
Solution Approach 1:
The patent merges the electrical connection function with mechanical attachment function into a single integrated structure. The bus bar assembly and printed circuit board assembly are combined with the stator core through a unified coupling mechanism that simultaneously provides both electrical connectivity and mechanical stability, eliminating the need for separate fastening components and ensuring reliable connections under high-temperature and high-vibration conditions.
Solution Approach 2:
The patent employs composite material structures that combine conductive and insulating properties within the coupling mechanism. The coupling structure integrates materials with different electrical properties to maintain electrical connectivity while providing mechanical strength and thermal stability, ensuring reliable electrical connections in demanding environmental conditions.
2Stability of the object's composition
If separate bus bar assembly and printed circuit board assembly are coupled to the stator, then manufacturing and assembly are straightforward, but mechanical stability deteriorates in high-vibration environments
Solution Approach 1:
The patent combines multiple assembly operations into a single integrated manufacturing process. The bus bar assembly and printed circuit board assembly are attached to the stator core simultaneously through a unified coupling mechanism, reducing the number of discrete assembly steps while enhancing mechanical stability through integrated structural design that resists high-vibration environments.
3Volume of moving object
If conventional attachment methods are used for securing motor components, then material usage is sufficient for structural integrity, but device size cannot be minimized
Solution Approach 1:
The patent employs thin-film and compact coupling structures that provide sufficient mechanical strength and electrical connectivity with minimal material usage. The integrated coupling mechanism uses optimized thin-walled structures and streamlined design elements that maintain structural integrity while significantly reducing the overall volume of the motor assembly.
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 solution provides a secure, reliable, and efficient method for assembling electric motor components, enhancing electrical connectivity and mechanical stability, while allowing for miniaturization and reduced material usage, thus improving the motor's performance and durability.
Implementation Method 1
made from thermoplastic materials that melt and bond upon cooling
Implementation Method 2
made from thermoplastic materials that melt and bond upon cooling
Implementation Method 3
a method involving ultrasonic welding, thermal pressing, or heat staking
Data Source
AI summary
An electric motor may include a rotor assembly including a rotor shaft defining a rotational axis. An electric motor may include a stator assembly including a core, an insulator at least partially covering the core, and a plurality of windings, the insulator defining one of a post that protrudes in an axial direction parallel with the rotational axis or a receptacle in which the post is receivable. An electric motor may include a bus bar assembly including a non-conductive body and a plurality of conductors configured to make an electrical connection between at least two windings of the plurality of windings, the non-conductive body including the other of the post or the receptacle, wherein the receptacle includes at least one of an aperture or a recess, and wherein the post is received within the receptacle to secure the non-conductive body to the insulator.