Stator with Annular Plate and Exposed Terminals
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Solution Overview
Problem
The existing method for manufacturing resin-molded stators is complex due to the need for multiple coil strands to be drawn out through holes corresponding to the number of teeth portions, and connecting bus bars to the coil strands after molding is cumbersome, especially with increased connection points.
Innovation Solution
A stator design featuring a stator core with coil strands wound around teeth portions, an annular plate overlapping the stator core, and terminals connected to the coil strand ends, where the stator core and plate are molded in resin with part of the terminals exposed, simplifying the connection process and reducing the number of connection points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire stator core is inserted in the resin to expose the coil strand for bus bar connection, then waterproofness is enhanced through insert molding, but the process becomes complicated and the number of connection points increases
Solution Approach 1:
The invention segments the coil structure by having coil strands wound around only specific tooth portions rather than all teeth, reducing the number of exposed ends that need to be connected to bus bars. This segmentation maintains the waterproof insert molding benefit while simplifying the connection process.
Solution Approach 2:
The invention extracts only the necessary coil strands that need to be connected to bus bars by having them wound around specific tooth portions, while other coil strands remain enclosed in the resin. This reduces the number of connection points and simplifies the overall process.
2Reliability
If coil strands are drawn out through hole portions corresponding to the number of teeth portions, then electrical connection is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The invention extracts only the necessary coil strands for electrical connection by winding them around specific tooth portions, while other strands remain enclosed. This reduces the number of holes needed and simplifies the manufacturing process while maintaining electrical connection reliability.
Solution Approach 2:
The tooth portions serve multiple functions: they provide structural support for the stator core and simultaneously serve as winding supports for coil strands that need electrical connection. This multi-functionality eliminates the need for separate hole portions, simplifying the manufacturing process.
Data Source
AI summary
A stator includes: a stator core in which a coil strand is wound around each of a plurality of teeth portions formed in an annular yoke portion; an annular plate that is disposed at a position overlapping an annular portion of the stator core in a direction along an axial center of the stator core; a plurality of terminals which are supported by the plate and to which end portions of a plurality of the coil strands drawn out from the stator core are respectively connected; and a resin that encloses the stator core and the plate in a state where a part of the plurality of terminals is exposed.