Motor Resin Casing Peeling Prevention
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Solution Overview
Problem
Molded resin motors face issues with resin peeling from the insulator, leading to noise and potential failure due to the thin resin portion between the center core of the mold and the insulator, which can come into contact with the rotor.
Innovation Solution
The motor design includes a resin casing with an annular inner resin portion and protruding portions that overlap with the wall portions, increasing the radial thickness and reducing peeling, achieved through a molding process using first and second molds with specific stepped surfaces and opposite surfaces to form recessed and protruding portions during the curing of the resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a thin resin portion is molded between the center core of the mold and the insulator to facilitate stator insertion, then the ease of manufacture is improved, but the reliability deteriorates due to peeling and potential contact with the rotor
Solution Approach 1:
The patent applies preliminary action by forming protruding portions on the inner resin portion before the molding process. These protruding portions are designed to overlap with the wall portions of the insulator in advance, ensuring that when the resin is molded, it will be securely positioned and prevented from peeling. This pre-configuration of the mold structure eliminates the need for thin resin portions while maintaining ease of manufacture and improving reliability.
2Reliability
If the radial thickness of resin inside the wall portions is increased to suppress peeling, then the reliability is improved, but the device complexity increases due to additional protruding portions and recessed portions
Solution Approach 1:
The patent applies local quality by strategically positioning protruding portions only in specific locations where the inner resin portion overlaps with the wall portions of the insulator. This localized approach increases resin thickness and peeling resistance only where needed, rather than uniformly throughout the entire structure. The recessed portions are similarly positioned to accommodate these protrusions, creating a targeted solution that improves reliability without unnecessarily complicating the overall device structure.
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
The increased radial thickness of the resin within the wall portions effectively suppresses peeling, enhancing the structural integrity and preventing resin contact with the rotor, thus reducing noise and failure risks.
Implementation Method 1
obtaining the resin casing by curing the resin that is in a flowing state
Data Source
AI summary
A method of molding a resin casing covering a stator of a motor may include preparing first and second molds; disposing the stator in the first mold; combining the molds; pouring a resin into the cavity; curing the resin; separating the molds; and taking the stator and resin casing from the mold. The stator may include a core, an insulator, and a coil. The core may include a core back surrounding and teeth that extend inward from the core back. The insulator may include wall portions inside the coil. The wall portions may be provided around the teeth and extend toward one side in an axial direction. One of the molds may include cylindrical surfaces contacting inner end faces of the teeth. The first mold may include wall supporting surfaces contacting or facing the inner surfaces of the wall portions. The wall supporting surfaces may be outside the cylindrical surfaces.