Motor Terminal Holder Structure for Simplified Insulation

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Solution Overview

Problem

The existing motor manufacturing process is complex and cumbersome due to the need for individually manufactured spacers for terminal insulation, leading to structural and manufacturing inefficiencies, and vulnerability to vibration, which damages the stator coil and reduces durability.

Innovation Solution

A motor design featuring an insert member that supports and insulates terminals without separate spacers, integrated with a holder using injection molding, and coupling protrusions that minimize displacement and secure the holder to the housing, reducing vibration-induced damage and simplifying the manufacturing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If spacers are individually manufactured for each terminal to provide electrical insulation, then terminal insulation is achieved, but the structure and manufacturing process become complicated and cumbersome

Engineering Contradiction:

Improveterminal insulationVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the functions of multiple individual spacers into a single integrated holder structure. The holder is designed with multiple insulating portions that simultaneously support and electrically insulate multiple terminals, eliminating the need for separate spacers for each terminal. This integration reduces structural complexity while maintaining the electrical insulation function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The holder serves multiple functions: it supports the terminals, provides electrical insulation between terminals, and maintains the spatial arrangement of terminals. By making the holder multi-functional, the patent eliminates the need for separate dedicated insulating components, thereby simplifying the overall structure.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple individual spacers are manufactured and assembled with terminals and insulating material, then terminal insulation is achieved, but the manufacturing process becomes complicated and cumbersome

Engineering Contradiction:

Improveterminal insulationVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the manufacturing of spacers and the holder into a single integrated component. The holder is manufactured as one piece with built-in insulating portions, eliminating the need for separate manufacturing and assembly steps for individual spacers and insulating material, thereby simplifying the manufacturing process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulating portions are pre-integrated into the holder structure during holder manufacturing, rather than being added as separate components during assembly. This preliminary integration of the insulation function into the holder design reduces the number of manufacturing steps and assembly operations required.

Inventive Principle:

Principle #10Preliminary action

3Device complexity

If the innermost peripheral portion of the holder is disposed in cantilever form, then the structure is simplified, but displacement increases under vibration and impact

Engineering Contradiction:

Improveholder structureVSAvoidholder displacement

Core Design Contradiction:

Device complexityVSStability of the object's composition

Solution Approach 1:

The holder is divided into multiple portions with different structural characteristics. The outer peripheral portion is designed with higher rigidity to resist vibration and impact, while the inner peripheral portion maintains a simplified cantilever structure. This segmentation allows different parts of the holder to have optimized properties for their specific functions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The holder exhibits local quality variations where the outer peripheral portion has enhanced rigidity compared to the inner peripheral portion. This local differentiation allows the holder to provide structural stability where needed (outer portion) while maintaining simplicity where less stress is applied (inner portion), resolving the contradiction between structural simplification and vibration resistance.

Inventive Principle:

Principle #3Local quality

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 structure and manufacturing process, enhances durability and stability, reduces vibration and noise, and minimizes costs while maintaining terminal insulation and arrangement effectively.

Implementation Method 1

a holder configured to surround the plurality of terminals and the insert member

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Implementation Method 2

integrated with a holder using injection molding

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS11855516B2Motor with simplified structure for insulating a terminal

Publication Date: 2023.12.26 HYUNDAI MOBIS CO LTD

AI summary

The present disclosure relates to a motor including: a plurality of terminals; an insert member configured to support the plurality of terminals spaced apart from one another; and a holder configured to surround the plurality of terminals and the insert member, thereby simplifying a structure and a manufacturing process and improving durability.