Electric Motor Stator Resin Molding Bracket Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing electric motor stators with resin-molded units face challenges in preventing resin flow from openings formed for lead extraction, which can lead to resin protrusion and hinder terminal box attachment.
Innovation Solution
A method involving attaching a hollow bracket to a stator core, allowing leads to pass through an opening, using a sealing member with a through-hole smaller than the opening to block resin flow, and filling molten resin between the stator core and core material to form resin units, ensuring the resin does not protrude from the outer peripheral surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an opening is formed in the bracket for lead extraction, then the lead can be taken out to the outside of the bracket, but the resin may flow out from the opening during injection molding
Solution Approach 1:
The opening in the bracket is segmented into two functional zones: an upper sealed portion that prevents resin leakage during injection molding, and a lower exposed portion that allows lead extraction. This segmentation enables the opening to simultaneously fulfill both containment and extraction functions without compromise.
2Productivity
If resin is injected by pressurization to fill the annular space, then the resin unit is formed between the stator core and core material, but resin may protrude from the opening and hinder terminal box attachment
Solution Approach 1:
The opening is designed with a sealed upper portion before the resin injection process begins. This preliminary sealing action prevents resin from escaping during the high-pressure injection process, ensuring that the resin fills the annular space completely and forms a precise surface position without protrusion that would interfere with terminal box attachment.
3Reliability
If the opening is completely sealed to prevent resin flow, then resin containment is improved, but lead extraction becomes difficult
Solution Approach 1:
The opening exhibits local quality variation along its length: the upper portion is sealed to provide resin containment, while the lower portion remains open to facilitate lead extraction. This localized differentiation of sealing properties allows the single opening structure to simultaneously achieve both resin containment and lead extraction functions.
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
Prevents resin outflow from the opening, allows easy attachment of the terminal box, maintains lead flexibility, and simplifies the resin molding process by eliminating the need for pressure-applying apparatuses.
Implementation Method 1
attaching a sealing member with a through-hole that is smaller than the opening to an outer peripheral surface of the bracket so as to block the opening while allowing the lead to pass through the through-hole
Implementation Method 2
filling a molten resin into an annular space between the stator core and the bore material, to form a resin unit
Data Source
AI summary
A method for manufacturing an electric motor stator, including: attaching a hollow bracket to an end of a hollow stator core and allowing a lead connected to the winding to pass through an opening formed in a peripheral surface of the bracket to take out the lead to an outside of the bracket; placing a core material inside the stator core and the bracket; attaching a sealing member to an outer peripheral surface of the bracket so as to block the opening while allowing the lead to pass through the through-hole; and filling a molten resin into an annular space between the stator core and the core material and between the bracket and the core material, to form a resin unit.