Overmolded Stator Core Insulation Mold Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional stator insulation for electric motors is expensive and difficult to fabricate, posing a challenge in the development of cost-effective and efficient motor designs.
Innovation Solution
An electrically insulative covering is overmolded onto a toroidal stator core with a mold that includes moveable cavity-defining portions and pins to secure the core, providing insulation while simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional stator insulation methods are used, then insulation is provided, but manufacturing cost increases and fabrication difficulty increases
Solution Approach 1:
The patent merges the insulation function with the stator core structure by overmolding the covering directly onto the core. This integration eliminates separate insulation components and assembly steps, reducing manufacturing complexity while maintaining insulation effectiveness. The covering becomes an integral part of the stator assembly rather than a separate component.
Solution Approach 2:
The overmolded covering serves multiple functions simultaneously: it provides electrical insulation, structural support, and mechanical protection for the stator core. This multi-functionality reduces the need for additional components and simplifies the overall manufacturing process while maintaining reliability.
2Reliability
If traditional stator insulation methods are used, then insulation is provided, but manufacturing cost increases
Solution Approach 1:
By combining the insulation covering with the stator core through overmolding, the patent reduces the total number of parts and assembly operations. This integration lowers manufacturing cost by eliminating separate insulation components, fasteners, and assembly steps while maintaining effective insulation.
3Manufacturing precision
If pins are used to secure the core in the mold cavity, then the core is held firmly, but the mold structure becomes more complex
Solution Approach 1:
The patent segments the mold structure into cavity-defining portions with integrated pins, allowing the pins to be positioned precisely at specific locations within the cavity. This segmentation enables accurate core positioning while keeping the overall mold design manageable through modular construction.
Solution Approach 2:
The pins act as intermediary elements between the mold cavity and the stator core, providing a simple yet effective mechanism for securing the core during the overmolding process. These pins facilitate precise positioning without requiring complex clamping or fastening systems.
Data Source
AI summary
A stator of an electric motor includes a core and a covering overmolded on the core. The mold for overmolding the covering on the core includes first and second cavity-defining portions and pluralities of first and second pins extending at least generally toward opposite ones of the cavity-defining portions. The cavity is configured to receive the core therein. The first pins and the second pins are configured to extend into the cavity when the mold is in the closed position to cooperatively at least in part secure the core in the cavity.