Motor Tab Terminal Segmentation for Resin Insulation

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Solution Overview

Problem

The challenge in manufacturing motors with aluminum coils is the difficulty in preventing resin from contacting the external electric terminal, which leads to manufacturing complexities and potential corrosion of aluminum due to its poor ductility and susceptibility to water, especially salt water.

Innovation Solution

The motor design includes a tab terminal divided into two portions, one connected to the coil and the other to the external electric terminal, with resin filling only the coil-connected portion, using a slit structure and a magmate to ensure electrical connection and prevent resin overflow to the external terminal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If resin fills in the entire tab terminal to seal and protect the coil, then the coil is protected from corrosion and insulation is improved, but the resin may contact and harden on the external electric terminal, causing manufacturing difficulty and potential electrical connection problems

Engineering Contradiction:

Improvecorrosion resistance and insulation of coilVSAvoiddifficulty of controlling resin application

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The tab terminal is divided into two distinct portions: a first portion for coil connection and a second portion for external electric terminal connection. This segmentation allows resin to be applied selectively only to the first portion, preventing contamination of the second portion while maintaining protective sealing where needed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the tab terminal are treated differently regarding resin application. The first portion receives resin filling for protection and insulation, while the second portion remains free of resin to ensure proper electrical connection. This local differentiation of treatment resolves the contradiction between protection and manufacturability.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If aluminum is used for the coil to reduce manufacturing cost and improve material availability, then manufacturing cost decreases, but aluminum's poor ductility makes it susceptible to breaking during winding and its weakness against water causes easy corrosion

Engineering Contradiction:

Improvemanufacturing cost and material availabilityVSAvoidstrength and corrosion resistance of coil

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The aluminum coil is combined with a protective resin coating applied to the tab terminal portion. This composite structure maintains the cost and availability advantages of aluminum while adding corrosion protection through the resin barrier, effectively addressing aluminum's weakness against water and corrosion.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Resin is applied in advance to the tab terminal portion before the coil is fully assembled and before any corrosion can occur. This preventive measure protects the aluminum coil from future corrosion exposure, compensating for aluminum's inherent weakness against water and salt water.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 motor manufacturing by preventing resin application to the external terminal and enhances the durability and corrosion resistance of the aluminum coil by sealing and insulating the coil connection area with resin.

Implementation Method 1

resin fills in and seals the coil connection space unit

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Implementation Method 2

prevent the corrosion, and insulate the end of the coil

Methodology Applied

Scientific EffectCorrosion prevention: Preservative

Data Source

PatentUS7906879B2Motor

Publication Date: 2011.03.15 NEW MOTECH

AI summary

The present invention provides a motor comprising: a stator which contains a core insulated with an insulator and wrapped with a coil therearound, wherein the coil includes an aluminum core wire with a coating film therearound; a tab terminal including at least one slit in which the coil is inserted; and a magmate that is inserted into the tab terminal by forming both the slit to which the coil is electrically connected through insertion and a contact unit which contacts the external electric terminal for an electric connection, characterized in that the tab terminal is divided by a barrier into a coil connection space unit and a terminal connection space unit, and the slit opened from the upper side to the lower side is formed on an outer wall of the coil connection space unit to allow the insertion of the coil.