Stator Bracket Seal Member Resin Leakage Prevention
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Solution Overview
Problem
Conventional electric motors with a stator core and bracket experience resin leakage during the filling process due to the lack of effective sealing at the opening for lead wires, which compromises cooling performance and manufacturing efficiency.
Innovation Solution
A method involving a seal member with a through hole and specific structural features, such as a slit and notch, is used to tightly contact the opening's wall surfaces, allowing the lead wire to be inserted and ensuring the seal member is deformed to prevent resin leakage by being held between a terminal plate and an abutting part, and optionally expanded thermally for enhanced sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an opening is formed in the bracket for leading out lead wires, then the lead wire can be led to the outside, but resin may leak out from the opening during the filling process
Solution Approach 1:
A seal member is introduced as an intermediary component between the bracket opening and the internal space. This seal member includes a through hole for the lead wire and elastic deformation capability, allowing it to simultaneously enable lead wire passage and prevent resin leakage by deforming to seal the opening.
Solution Approach 2:
The seal member utilizes elastic deformation (change in physical state) to transition from a non-sealing state during assembly to a sealing state during resin filling. The elastic property allows the seal member to deform and tightly contact the bracket wall surface, preventing resin leakage while maintaining lead wire accessibility.
2Reliability
If a seal member is arranged in the opening to prevent resin leakage, then resin sealing is improved, but the structure becomes more complex
Solution Approach 1:
The seal member is designed as a flexible component with elastic deformation capability that can be pressed against the bracket opening. This flexible structure achieves effective sealing without requiring complex rigid sealing mechanisms, maintaining simplicity while improving reliability.
Solution Approach 2:
The seal member is divided into functional segments: a through hole for lead wire passage and an elastic body for sealing. This segmentation allows each part to perform its specific function efficiently, achieving both lead wire accessibility and resin sealing without unnecessary structural complexity.
3Reliability
If the seal member is deformed by holding between terminal plate and abutting part, then sealing contact is tightened, but the manufacturing process becomes more complex
Solution Approach 1:
The seal member is pre-positioned in the opening before resin filling, and the terminal plate and abutting part are designed to automatically deform the seal member during assembly. This preliminary positioning combined with automatic deformation during assembly simplifies the manufacturing process while ensuring reliable sealing contact.
Solution Approach 2:
The seal member utilizes its own elastic property to automatically deform and seal the opening when pressed between the terminal plate and abutting part. This self-deforming mechanism eliminates the need for additional sealing operations or complex assembly steps, improving ease of manufacture while maintaining reliable sealing.
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 method effectively prevents resin leakage during the filling process, improving heat dissipation and manufacturing efficiency without requiring special molds, while ensuring reliable insulation of lead wires.
Implementation Method 1
The seal member may have a coefficient of elasticity lower than the bracket. In this case, the step of arranging the seal member in the opening may include inserting the seal member into the opening so as to abut against the abutting part from the outside in the radial direction; pressing the terminal plate for receiving the lead wire against the seal member from the outside in the radial direction; deforming the seal member by holding the seal member between the terminal plate and the abutting part
Implementation Method 2
The seal member may have a coefficient of thermal expansion higher than the bracket. In this case, the step of arranging the seal member in the opening may include expanding the seal member by heating the seal member
Data Source
AI summary
A method of producing an electric motor which can prevent resin from ending up leaking from an opening for lead wire use when performing a step of filling a resin in the internal space of the electric motor, provided with a step of attaching a bracket which has an opening for leading lead wires of a coil to the outside, a step of arranging a seal member which has through holes which hold the lead wires at the opening so as to tightly contact without clearance the wall surfaces which define the opening while passing the lead wires through the through holes, and a step of filling a resin in the internal space which is defined by the bracket and the stator core.