Resolver Stator Circuitry Holder Layout for Corrosion Isolation
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Solution Overview
Problem
Resolvers used in corrosive environments, such as with automatic transmission fluid, face issues of galvanic corrosion leading to short circuits due to conductive paths between contacts, which reduces accuracy and is costly to address with existing epoxy sealant solutions.
Innovation Solution
Increasing the creepage distance between contacts to at least 4 mm, achieved through structural modifications like trenches and walls on the mounting surface, and using clamping connections to reduce the probability of short circuits and minimize installation space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the creepage distance between contacts is increased to prevent short circuits in corrosive environments, then reliability is improved, but the device complexity and installation space increase
Solution Approach 1:
The mounting surface is segmented into distinct regions separated by trenches and walls, creating isolated contact zones. This segmentation increases the creepage distance between contacts by dividing the continuous surface into separated segments, preventing conductive path formation while maintaining a compact overall structure.
Solution Approach 2:
The patent introduces vertical dimensionality to the mounting surface by adding walls and trenches that protrude from or recess into the surface. This transforms a two-dimensional contact layout into a three-dimensional structure, increasing the effective creepage distance without proportionally increasing the planar footprint, thus addressing space constraints.
2Reliability
If epoxy sealant is used to protect contacts from corrosive fluids, then reliability is improved, but manufacturing cost increases
Solution Approach 1:
The mounting surface structure itself provides the protective function by using trenches and walls to physically block corrosive fluids from reaching the contacts. This self-protecting design eliminates the need for additional protective materials like epoxy sealant, reducing manufacturing complexity and cost while maintaining reliability.
Solution Approach 2:
The protective function is extracted from the epoxy sealant material and integrated directly into the mounting surface geometry. By embedding the protection mechanism within the structural design rather than adding a separate protective layer, the patent eliminates the need for costly sealing materials and simplifies the manufacturing process.
3Reliability
If the creepage distance is increased to maintain accuracy, then reliability is improved, but the installation space increases
Solution Approach 1:
By utilizing the vertical dimension through walls and trenches, the patent increases the effective creepage distance without proportionally increasing the planar area. The three-dimensional structure allows for greater electrical isolation within a compact footprint, maintaining accuracy requirements while minimizing installation space.
Solution Approach 2:
The trenches and walls are nested within the mounting surface boundaries, creating a compact configuration where protective structures are contained within the overall device envelope. This nesting approach maximizes the creepage distance within the available space without requiring additional installation area.
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
The increased creepage distance effectively reduces the occurrence of short circuits and corrosion, maintaining resolver accuracy while minimizing costs and installation space, even in corrosive environments.
Implementation Method 1
In combination with the electro-galvanic effect, conductive circuits can occur between the metal contacts
Implementation Method 2
In combination with the electro-galvanic effect, conductive circuits can occur between the metal contacts
Data Source
AI summary
A circuitry holder of a resolver's stator for coupling coils of a resolver to an electric circuitry includes a mounting surface with a first contact holder that clamps a first contact for connecting a first terminal of the resolver to the electric circuitry and a second contact holder that clamps a second contact for connecting a second terminal of the resolver to the electric circuitry, wherein a creepage distance between the first contact and the second contact is greater than or equal to 4 mm, the creepage distance is the shortest distance between the first contact and the second contact along the mounting surface of the circuitry holder, the creepage distance for avoiding the generation of short circuits between the first contact and the second contact when the mounting surface is contacting a corrosive fluid.