Resin Power Feed Structure for Electric Motor
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Solution Overview
Problem
The existing power supply unit structure for electric motor apparatuses, such as those used in electric power steering, increases the number of components and costs due to the insert-molding of copper members into synthetic resin bodies, compromising insulation and dimensional accuracy.
Innovation Solution
A power supply unit structure where the connection terminals and power supply terminals are held by a common resin holding member, with a press-fitting mechanism where the press-fitted portion is long in the plate width direction and short in the plate thickness direction, allowing the power supply terminal to be press-fitted into the center portion of the holding member, reducing the number of components and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If copper members are insert-molded into synthetic resin bodies to maintain insulation property and enhance dimensional accuracy, then insulation property and dimensional accuracy are improved, but the number of components and cost increase
Solution Approach 1:
The patent merges the holder body and holder terminals into a single integrated component made of resin. The holder terminals are formed as integral parts of the holder body through molding, eliminating the need for separate copper members and insert-molding processes. This reduces the number of components while maintaining dimensional accuracy and insulation properties.
Solution Approach 2:
The patent changes the material parameter from copper to resin for the holder terminals. By using resin material that can be directly molded into the holder body, the invention eliminates the need for insert-molding copper terminals, thereby reducing component count and manufacturing complexity while maintaining the required electrical and mechanical functions.
2Manufacturing precision
If copper members are insert-molded into synthetic resin bodies to maintain insulation property and enhance dimensional accuracy, then insulation property and dimensional accuracy are improved, but cost increases
Solution Approach 1:
The patent combines the holder body and holder terminals into a single molded part, eliminating the need for separate copper terminal components and the complex insert-molding process. This single-molding approach reduces manufacturing steps, material costs, and assembly operations, thereby lowering overall production cost while maintaining dimensional accuracy.
Solution Approach 2:
The patent replaces expensive copper terminals with resin terminals that are molded directly into the holder body. This substitution with a cheaper material that can be directly formed reduces material cost and eliminates the need for expensive insert-molding processes, making the manufacturing more cost-effective.
3Manufacturing precision
If the press-fitted portion is long in plate width direction and short in plate thickness direction, then positional accuracy is enhanced, but uneven press-fitting forces may occur
Solution Approach 1:
The patent applies local quality by creating a press-fitted portion with non-uniform dimensions - longer in the plate width direction and shorter in the plate thickness direction. This localized dimensional variation allows the press-fitted portion to be press-fitted into the center of the holder body, enhancing positional accuracy while the specific geometry distributes press-fitting forces to prevent excessive unevenness.
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 configuration suppresses the increase in the number of components and costs, enhances positional accuracy, and simplifies assembly while maintaining dimensional accuracy, thereby reducing the risk of uneven press-fitting forces and loss torque.
Implementation Method 1
the power supply terminal includes a press-fitting portion press-fitted into a press-fitted portion of the holding member
Data Source
AI summary
The connection terminal and the power supply terminal are held by a common holding member made of a resin. The power supply terminal includes a press-fitting portion press-fitted into a press-fitted portion of the holding member. The press-fitted portion of the holding member has a shape that is long in a plate width direction of the power supply terminal and short in a plate thickness direction of the power supply terminal. Assuming that a dimension of each of both end portions of the press-fitted portion in the plate width direction of the power supply terminal is defined as L1, a dimension of a center portion of the press-fitted portion is defined as L2, and a plate thickness of the power supply terminal is defined as T, L2<T<L1 is satisfied under a non-press-fitted state.