Overmolded Stator-Housing Assembly for High-Load Motor Attachment
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Solution Overview
Problem
Existing electric motor designs face challenges in securely attaching larger, heavier electronics and fan wheels due to the limitations of screw connections in the insulation, particularly in larger motors, where the attachment method is not robust enough to withstand significant loads.
Innovation Solution
The solution involves overmolding a heat-conducting, electrically insulating plastic material around both the stator and the electronics/terminal housing, creating a form-locked connection that eliminates the need for additional connecting parts and enhances heat dissipation, while allowing for the passage of components like sensors and fastening screws.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screw connections are used to attach electronics housing to stator, then assembly is simple, but the connection strength is insufficient for larger, heavier motors
Solution Approach 1:
The patent merges the insulation overmolding with the connecting function by integrating fastening elements directly into the overmolding structure. The overmolding material itself forms the connection between stator and electronics housing, eliminating the need for separate screw connections while providing sufficient strength for larger motors.
Solution Approach 2:
The patent uses composite construction by combining the overmolding material with embedded fastening elements (such as metal inserts or reinforced structures) within the insulation layer. This creates a hybrid connection system that leverages both the electrical insulation properties of the overmolding and the mechanical strength of the embedded elements.
2Strength
If additional connecting parts are used to strengthen the attachment, then connection strength improves, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple functions into the overmolding process itself. The insulation application and connection creation are performed in a single manufacturing step, where fastening elements are embedded during the overmolding process rather than being added as separate assembly steps.
Solution Approach 2:
The fastening elements are pre-positioned and embedded within the overmolding material before the final curing process. This preliminary placement ensures proper alignment and integration, simplifying the overall manufacturing process while maintaining connection strength.
3Stability of the object's composition
If the overmolding covers the entire bottom of electronics housing, then connection stability improves, but heat dissipation may be compromised
Solution Approach 1:
The patent applies different properties to different regions of the overmolding structure. The overmolding material has varying thermal conductivity in different areas, with higher conductivity regions positioned to facilitate heat dissipation from critical components while maintaining structural integrity and connection stability in other areas.
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 method provides a reliable, form-locked connection that securely attaches the electronics/terminal housing to the stator, ensuring stability under heavy loads and facilitating assembly, while also improving heat dissipation and reducing the complexity of the manufacturing process.
Implementation Method 1
The material of the overmolding enables an optimal heat dissipation from the winding region of the stator into the electronics and/or terminal housing
Data Source
AI summary
The invention relates to an electric motor comprising a stator (A) with an insulation, a rotor, and an electronics and/or terminal housing (1) comprising a bottom (4), in which electrical/electronic components provided for the operation of the electric motor are housed. The electronics and/or terminal housing (1) is permanently connected to the stator (A) by means of an overmould (17b) so as to form a stator unit, the bottom (4) of the electronics and/or terminal housing (1) being at least partially covered by the overmould (17b) on its upper side. The overmould is not only provided for the stator, but is used at the same time as a connection means for connecting the electronics and/or terminal housing to the wound stator. Additional connection parts are not required as a result. The stator packet is first wound and then inserted into an injection mould with the electronics housing (1). Then, a heat-conductive, electrically insulating plastic is used to form the overmould (17b). Said overmould permanently connects the stator and the electronics and/or terminal housing (1) together to form the stator unit. As the bottom (4) of the electronics and/or terminal housing (1) is at least partially covered on the upper side by the overmould (17b), a secure interlocking connection is ensured between the electronics and/or terminal housing (1) and the stator (A).