Resolver Stator Terminal Block for Weld-Free Magnet Wire Joining

The patent replaces TIG welding (thermal/mechanical process) with insert molding (mechanical embedding process). The terminal pin is embedded into the resin insulator housing, creating a mechanical connection that avoids the thermal effects and wire thinning associated with welding. This substitution eliminates the harmful thermal field while maintaining connection strength through mechanical interlocking.

The patent introduces resin insulator housing as an intermediary material between the terminal pin and the external environment. This intermediary provides both mechanical support and electrical insulation, allowing the terminal pin to be securely held without direct welding to the wire. The resin acts as a buffer that distributes stress and prevents wire breakage.

The patent replaces the welding-based electrical connection with a mechanical embedding system. The terminal pin is inserted into the resin insulator housing where it is mechanically secured and electrically connected to the magnet wire through direct contact and binding, eliminating the need for welding and the associated length requirements.

The patent transitions from a one-dimensional welding connection (requiring axial length) to a three-dimensional embedding structure. The terminal pin is surrounded and supported by the resin insulator housing in multiple dimensions, allowing for shorter axial length while maintaining connection reliability through volumetric support.