Rotary Motor Terminal Segmentation for Soldering and Molding
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Solution Overview
Problem
Conventional rotary electric motors face challenges in terminal connection and molding processes, where tie portions are buried in resin, leading to increased external-power-supply connection thickness, solder attachment issues, and complex manufacturing procedures.
Innovation Solution
The rotary electric motor features terminals with two protrusions - a permanent press-fitting portion for secure attachment and a temporary press-fitting portion for soldering, allowing simultaneous immersion in solder and subsequent resin molding with exposed external-power-supply connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If tie portions are buried in resin molding material, then manufacturing is simplified, but external-power-supply connection portions cannot be covered by terminal caps and connection failures occur
Solution Approach 1:
The terminal is divided into distinct functional portions: tie portions for soldering (buried in resin) and external-power-supply connection portions for external connections (exposed). This segmentation allows each portion to be positioned according to its specific function, resolving the conflict between molding simplicity and connection reliability.
Solution Approach 2:
The terminal structure utilizes spatial arrangement in three dimensions, with tie portions positioned lower to be buried in resin and external-power-supply connection portions positioned higher to remain exposed. This dimensional arrangement allows both requirements to be satisfied simultaneously.
2Productivity
If tie portions are located near insulators, then simultaneous immersion in solder bath is enabled, but solder attaches to external-power-supply connection portions increasing thickness
Solution Approach 1:
The terminal structure provides different local properties: tie portions are positioned to be immersed in solder bath for efficient soldering, while external-power-supply connection portions are positioned higher to remain exposed and maintain precise thickness control. This local differentiation resolves the contradiction between soldering efficiency and dimensional precision.
3Reliability
If external-power-supply connection portions are exposed, then terminal caps can cover them and connection reliability improves, but tie portions cannot be buried in resin
Solution Approach 1:
The terminal is segmented into tie portions (buried in resin for manufacturing simplicity) and external-power-supply connection portions (exposed for reliability). This segmentation allows the molding process to be simple while ensuring external connections remain accessible and reliable.
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 design improves terminal quality and simplifies manufacturing by enabling simultaneous soldering of tie portions and exposing external-power-supply connections from the resin molding, reducing solder attachment and connection failures.
Implementation Method 1
a permanent press-fitting portion for press-fitting one of the terminals into the corresponding one of the insulators
Implementation Method 2
a temporary press-fitting portion for temporarily press-fitting the one of the terminals when the corresponding one of the coil terminal lines is joined to the one of the terminals with solder
Implementation Method 3
the tie portions are immersed into a solder bath, and solder is attached also to the external-power-supply connection portions
Data Source
AI summary
A rotary electric motor includes an annular stator, a rotor rotatably held on an inner circumferential side of the stator, a plurality of stator cores forming the stator, insulators attached to the stator cores and formed of an insulating material, coils wound around the insulators, and a plurality of terminals to which coil terminal lines of the coils are connected. Each of the terminals includes at least two protrusions protruding from a substrate. The at least two protrusions are formed of a permanent press-fitting portion for press-fitting one of the terminals into the corresponding one of the insulators and a temporary press-fitting portion for temporarily press-fitting the one of the terminals when the corresponding one of the coil terminal lines is joined to the one of the terminals with solder.