Motor Housing Insert Injection Molding for Reliability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing motor assembly process is costly and unreliable due to individually assembled components, leading to manufacturing cost increases and reliability issues caused by component tolerances and spatial limitations.
Innovation Solution
A motor housing design where a busbar terminal and bearing are insert-injection-molded within the housing, and a connector part is integrally formed, simplifying the assembly process and improving insulation and waterproof properties by using different materials for the housings and forming centering ribs for improved adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If components are individually assembled in the housing during the assembly process, then the manufacturing flexibility is maintained, but the manufacturing cost increases and the reliability declines due to gaps from component tolerances
Solution Approach 1:
The busbar terminal and bearing are integrated into a single housing component through insert injection molding, eliminating the need for separate assembly steps. This merging of components removes gaps between parts, improving reliability while reducing assembly complexity.
Solution Approach 2:
The busbar terminal and bearing are pre-formed and inserted into the housing during the injection molding process itself, rather than being assembled separately afterward. This preliminary action ensures precise positioning and eliminates tolerance accumulation, improving reliability without adding assembly steps.
2Ease of manufacture
If multiple components are assembled separately, then the manufacturing process is flexible, but the manufacturing cost increases due to individual assembly requirements
Solution Approach 1:
Multiple components (housing, busbar terminal, bearing) are combined into a single integrated part manufactured in one injection molding cycle. This eliminates separate assembly operations, reducing manufacturing cost while ensuring precise fit without gaps.
Solution Approach 2:
The insert injection molding process acts as an intermediary method that combines the advantages of separate component manufacturing with integrated assembly. Pre-formed inserts are embedded during molding, achieving both cost efficiency and precision.
3Device complexity
If the housing is formed as a single integrated structure, then the assembly process is simplified and reliability is improved, but the manufacturing complexity increases due to insert-injection-molding requirements
Solution Approach 1:
Complex components like the busbar terminal and bearing are pre-formed separately using standard manufacturing processes, then inserted into the housing during injection molding. This preliminary preparation simplifies the main molding process while maintaining manufacturing feasibility.
Solution Approach 2:
The insert injection molding technique serves as an intermediary process that bridges simple component fabrication with complex integrated structure creation. It allows standard parts to be combined with the housing in a single operation without requiring advanced molding tools.
4Reliability
If different materials are used for the first housing and second housing, then insulation and waterproof properties are improved, but the manufacturing precision requirements increase
Solution Approach 1:
The housing is constructed from multiple materials (synthetic resin for the first housing, metal for the second housing) joined through injection molding. This composite structure provides both insulation from the resin portion and structural integrity from the metal portion, while the molding process ensures precise joining.
Solution Approach 2:
Traditional mechanical joining methods (screws, welds) between different materials are replaced with injection molding, which creates a monolithic bond. This substitution eliminates the precision requirements for mechanical fastening while achieving reliable material joining.
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 simplifies the motor assembly, minimizes component gaps, enhances reliability, and improves adhesion between the motor housing and cover, leading to reduced manufacturing costs and increased reliability.
Implementation Method 1
the busbar terminal and the bearing are internally insert-injection-molded in the first housing
Implementation Method 2
a centering rib formed to center the cover is improved
Data Source
AI summary
One embodiment relates to a motor comprising: a motor housing comprising a first housing and a second housing; a stator disposed in the motor housing; a coil wound around the stator; a rotor rotatably disposed in the stator; a shaft coupling with the rotor; a bearing for supporting the shaft; and a busbar terminal connected with an end portion of the coil, wherein the first housing comprises a body part and a first flange, the body part comprising a first region, and a second region extending from the first region, and the first flange extending in a vertical direction from an end portion of the second region, and the busbar terminal and the bearing are disposed in the first region. Accordingly, the structure of the motor may be simplified, and a gap due to tolerance among components may be minimized, and thus the reliability of the motor may be enhanced.