Miniature Motor Stator Duroplastic Coating
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Solution Overview
Problem
Electric motors used in medical and dental technology face challenges with existing insulation methods, including time-consuming and costly casting processes using harmful resins, limited temperature resistance, and the inability to withstand sterilization procedures, especially when integrating electronic components.
Innovation Solution
A miniature electric motor design featuring a stator core coated with duroplastic material using injection molding or transfer molding, providing a sterilization-proof, thermally stable, and environmentally friendly insulation that encases both coil elements and electronic components, allowing for hermetic sealing and integration of cooling and media channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If casting resins are used for insulation, then temperature resistance and media resistance are improved, but the process becomes time-consuming and costly
Solution Approach 1:
The patent changes the material parameter from thermosetting casting resin to thermoplastic material, enabling processing at lower temperatures and shorter times while maintaining insulation performance through optimized material composition and processing parameters
Solution Approach 2:
The patent replaces the complex casting process (vacuum/pressure application followed by heat drying) with a simpler injection molding or transfer molding process that achieves insulation in one step without requiring subsequent drying operations
2Reliability
If casting resins are used for insulation, then temperature resistance and media resistance are improved, but the process becomes costly
Solution Approach 1:
The patent changes the material parameter from thermosetting casting resin to thermoplastic material, enabling processing at lower temperatures and shorter times while maintaining insulation performance through optimized material composition and processing parameters
Solution Approach 2:
The patent replaces the complex casting process (vacuum/pressure application followed by heat drying) with a simpler injection molding or transfer molding process that achieves insulation in one step without requiring subsequent drying operations
3Ease of manufacture
If thermoplastics are used in injection molding, then manufacturing simplicity is improved, but temperature resistance deteriorates
Solution Approach 1:
The patent uses composite thermoplastic materials with enhanced thermal stability, combining base thermoplastic polymers with heat-resistant additives or fillers to achieve both processing simplicity and high-temperature resistance
Solution Approach 2:
The patent optimizes the thermoplastic material composition and processing parameters to extend the service temperature range while maintaining the advantages of injection molding and transfer molding processes
4Ease of manufacture
If thermoplastics are used in injection molding, then manufacturing simplicity is improved, but sterilization resistance deteriorates
Solution Approach 1:
The patent uses composite thermoplastic materials with enhanced thermal stability, combining base thermoplastic polymers with heat-resistant additives or fillers to achieve both processing simplicity and high-temperature resistance
Solution Approach 2:
The patent optimizes the thermoplastic material composition and processing parameters to extend the service temperature range while maintaining the advantages of injection molding and transfer molding processes
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 solution enables the use of standard electronic components, ensures sterilization-proof operation, reduces manufacturing costs, and allows for compact, lightweight designs with integrated cooling and media routing within the motor, suitable for repeated sterilization and disinfection processes.
Implementation Method 1
a coating made of duroplastic material applied by an injection molding or transfer molding process
Implementation Method 2
a coating made of duroplastic material applied by an injection molding or transfer molding process
Implementation Method 3
the stator is hermetically sealed with the winding
Implementation Method 4
providing a sterilization-proof, thermally stable, and environmentally friendly insulation
Data Source
Figure 1~3
Figure 4~7
Figure 8~11
AI summary
An electric motor (1) is used to drive rotating tools of very small dimensions for medical technology applications. To protect against chemicals, disinfection and/or sterilization processes, the electric motor (1) and its electronic components (18) are encased in a coating (10) made of a special plastic, in particular a thermosetting material, that meets the requirements. Despite its small size, the design allows cable systems (11, 22a, 22b) to be routed axially through the electric motor (1), thus providing a direct connection from a power supply system to the electric motor (1) itself, or to the tool and the user's work area.