Overmolded Stator Structure for Fluid-Isolated Water Pumps
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Solution Overview
Problem
Existing water pumps have complex structures and large sizes due to numerous parts, and integrating the stator, can, and connector through overmolding exposes the stator's inner circumferential surface, leading to potential corrosion and insulation failure from fluid contact.
Innovation Solution
An overmolding stator design where the stator core and primary molding part are embedded within a secondary molding part, with a mold loading part exposed to prevent the stator's surface from being exposed, using a mold loading part to secure the assembly during molding and ensure insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the stator, can, and connector are integrated through overmolding to reduce parts and size, then the water pump complexity and size are reduced, but the stator's inner circumferential surface becomes exposed to fluid contact causing corrosion and insulation failure
Solution Approach 1:
The patent implements a nested structure where the stator core is embedded within the primary molding part, which is in turn embedded within the secondary molding part. This multi-layer nesting ensures that the stator's inner circumferential surface is completely enclosed and isolated from fluid contact, preventing corrosion and insulation failure while maintaining the integrated design benefits.
Solution Approach 2:
The patent introduces the primary molding part as an intermediary layer between the stator core and the secondary molding part. This intermediary structure serves as a protective barrier that prevents fluid from reaching the stator's inner circumferential surface, thereby maintaining insulation reliability while enabling the integrated overmolding design.
2Ease of manufacture
If the stator core is fixed to the mold for overmolding, then the molding process is simplified, but the inner circumferential surface of the stator core is exposed to the outside of the molding part
Solution Approach 1:
The patent employs nested molding where the stator core is first molded with the primary molding part, and then the secondary molding part is molded over it. This nested approach ensures complete surface coverage of the stator core while maintaining a straightforward two-stage molding process that is easy to manufacture.
3Device complexity
If the stator core surface is exposed to fluid, then the molding structure is simpler, but corrosion and insulation failure occur
Solution Approach 1:
The primary molding part acts as an intermediary protective layer between the stator core and the fluid environment. This intermediary structure prevents harmful fluid contact with the stator surface while maintaining a relatively simple overall molding structure with only two molding stages.
Solution Approach 2:
The nested arrangement of the stator core within the primary molding part, which is itself nested within the secondary molding part, creates a protective enclosure that isolates the stator surface from fluid exposure while keeping the molding structure straightforward and manufacturable.
Data Source
AI summary
Provided is an overmolding stator including: a stator core having a central portion open in a vertical direction; a primary molding part molded to surround the stator core and having a mold loading part formed to protrude radially outward beyond an outer circumferential surface of the stator core; and a secondary molding part molded to surround the stator core and the primary molding part, wherein the stator core and the primary molding part are embedded inside the secondary molding part, and the mold loading part of the primary molding part is exposed to the outside of the secondary molding part.