Motor Wire Terminal Structure for Thermal Stress Isolation
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Solution Overview
Problem
Existing motor designs face issues with stress transmission from wire terminals to substrates, leading to potential circuit damage due to thermal expansion and resin-sealing, which can cause bending and further damage.
Innovation Solution
Incorporating an elastic section between the substrate connection and leg of the wire terminal to absorb stress, and using a resin-sealed member that exposes the elastic section, allowing it to absorb thermal expansion stress without transferring it to the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the substrate connection section is inserted in a hole of the substrate to connect by soldering, then electrical connection is achieved, but stress is applied to the substrate which damages the circuit
Solution Approach 1:
The elastic section serves as an intermediary element between the rigid substrate connection section and the flexible wire terminal. This mediator absorbs and isolates stress, preventing direct transmission to the substrate while maintaining electrical connection reliability through the elastic section's ability to deform and return to its original shape.
2Temperature
If heat generated by the coil is transferred to the wire terminal causing thermal expansion, then heat dissipation occurs, but the substrate bends which damages the circuit
Solution Approach 1:
The elastic section changes its physical parameters (shape and length) in response to thermal expansion. When the wire terminal expands due to heat from the coil, the elastic section deforms to accommodate this expansion, preventing the transmitted force from bending the substrate while still allowing heat dissipation.
3Reliability
If the wire terminal is resin-sealed, then protection and insulation are improved, but thermal expansion causes substrate bending which damages the circuit
Solution Approach 1:
The elastic section acts as a stress-isolating intermediary between the resin-sealed wire terminal and the substrate. When the resin-sealed wire terminal undergoes thermal expansion, the elastic section absorbs the resulting forces, preventing them from reaching the substrate while maintaining the protective and insulating benefits of resin sealing.
4Stability of the object's composition
If the wire terminal is made rigid for stable connection, then connection stability is improved, but stress transmission to substrate increases
Solution Approach 1:
The wire terminal is segmented into distinct functional sections: a rigid substrate connection section for stable electrical connection, a flexible elastic section for stress absorption, and a rigid wire connection section for secure wire attachment. This segmentation allows each part to perform its specific function optimally without compromising the others.
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 solution effectively suppresses stress transmission to the substrate, preventing circuit damage from thermal expansion and resin-sealing, while facilitating easier attachment of terminals and reducing the risk of substrate bending.
Implementation Method 1
an elastic section that is elastically deformable between the plate section and the substrate connection section
Implementation Method 2
heat generated by the coil is transferred to the wire terminal to cause thermal expansion of the wire terminal at the time of driving the motor
Data Source
AI summary
In a motor, a wire terminal, to which an end at an end of winding of a wire is connected, is held by an insulator that is held by a stator core. The wire terminal comprises: a substrate connection section; plural legs held by a split insulator; a plate section, a thickness direction of which faces a radial direction, between the legs and the substrate connection section; and a wire connection section, a portion of which projected from the plate section is bent to hold the wire on an inner side. An elastic section is a meandering section meandering to turn back in a circumferential direction between the plate section and the substrate connection section, and extends from an end on another side in the circumferential direction of the plate section toward the substrate connection section.