Motor Stator Fixing Hole Structure for Secure Bracket Mounting
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Solution Overview
Problem
Existing electric motors face issues with insufficient fixation of components like brackets to the stator due to inadequate machining accuracy of molded resins, leading to vibration and noise, especially when using thermoplastic resins.
Innovation Solution
The electric motor design incorporates a stator with a thermosetting resin molded together with a thermoplastic resin component, featuring a fixing hole with a decreasing inside diameter, allowing secure screw fixation and reduced vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a screw hole is formed directly in a molded resin that is molded unitedly with the stator core, then the manufacturing process is simplified, but appropriate machining accuracy cannot be achieved and the screw cannot be sufficiently fixed
Solution Approach 1:
The patent divides the molded resin into two separate components: a thermosetting resin component and a thermoplastic resin component. The thermoplastic resin component is specifically designed to include the fixing hole, while the thermosetting resin provides the stator core structure. This segmentation allows the thermoplastic resin to be optimized for precise hole formation and screw fixation, while the thermosetting resin maintains structural integrity.
Solution Approach 2:
The patent employs a composite structure combining two different resin materials with distinct properties. The thermosetting resin provides rigidity and structural support for the stator core, while the thermoplastic resin provides ease of machining and precise hole formation. This composite approach resolves the contradiction by allowing each material to excel at its specific function.
2Ease of manufacture
If a screw hole is formed directly in a molded resin, then the manufacturing process is simplified, but the screw cannot be sufficiently fixed to the molded resin
Solution Approach 1:
The patent separates the functions of structural support and screw fixation into different resin components. The thermoplastic resin component, which contains the fixing hole, is specifically designed to provide reliable screw fixation, while the thermosetting resin provides the overall stator structure.
Solution Approach 2:
The patent applies different material properties to different parts of the molded resin structure. The thermoplastic resin component is specifically engineered with appropriate hardness and machinability characteristics to ensure reliable screw fixation, while the thermosetting resin provides structural integrity. This local optimization of material properties ensures both reliability and ease of manufacture.
3Ease of manufacture
If the inside diameter of the fixing hole is uniform, then manufacturing is easier, but the screw cannot be sufficiently fixed due to inadequate engagement
Solution Approach 1:
The patent designs the fixing hole with an asymmetric diameter profile: the upper portion has a larger diameter for easy screw insertion and alignment, while the lower portion has a smaller diameter for secure engagement. This asymmetric design resolves the contradiction by providing both manufacturing ease and strong fixation.
Solution Approach 2:
The varying diameter of the fixing hole creates a dynamic engagement structure that adapts to the screw during insertion. The larger upper diameter facilitates easy insertion, while the smaller lower diameter provides progressive engagement and secure fixation, optimizing both manufacturing ease and fixation strength.
Data Source
AI summary
An electric motor includes a rotor, a stator, a bracket, and a screw. The stator includes a stator core, a resin component having a fixing hole, and a molded resin molded unitedly with the stator core and the resin component. The molded resin is a thermosetting resin, The resin component is a thermoplastic resin. The resin component includes an opening and a bottom. An inside diameter of the fixing hole decreases from the opening to the bottom.