Stator Circuit Board Contact via Insulation Displacement
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Solution Overview
Problem
Existing solutions for connecting stators to circuit boards in electric motors are complex, costly, and labor-intensive, often requiring multiple parts and connections that complicate the production process.
Innovation Solution
A method utilizing insulation displacement contact elements on a stator housing to establish electrical contact with jumper wires on a circuit board, where the contact elements cut through the insulation to create a simple, compact, and efficient connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding or soldering is used to connect enameled wires to intermediate clamps and then to the conducting structure, then electrical connection is established, but the production becomes relatively expensive and the connection can be affected by defective welding
Solution Approach 1:
The patent replaces the thermal/mechanical welding process with a mechanical insertion process. Connection clamps with insertion ends are simply inserted into connection openings in the circuit board, eliminating the need for welding or soldering operations. This mechanical substitution resolves the contradiction by providing reliable electrical connection through direct metal-to-metal contact without the complexity and cost of thermal processing.
Solution Approach 2:
The connection clamps are designed to establish electrical connection automatically upon insertion into the circuit board. The insertion end of the connection clamp directly contacts the conducting structure through the connection opening, creating a self-establishing electrical connection without requiring additional welding operations or intermediate processing steps.
2Ease of manufacture
If connection clamps are inserted into connection openings to establish electrical connection, then production cost is reduced, but the connection process requires precise alignment and insertion
Solution Approach 1:
The connection openings in the circuit board serve as intermediaries that guide and position the insertion ends of the connection clamps. The openings are designed with specific dimensions and positions that automatically align the connection clamps with the conducting structure, eliminating the need for high-precision manual alignment while maintaining reliable electrical connection.
Solution Approach 2:
The connection openings are pre-formed in the circuit board at precise positions before the connection clamps are inserted. This preliminary preparation of the mounting positions ensures that when the connection clamps are inserted, they automatically achieve the correct alignment and positioning, reducing the precision requirements during the actual connection process.
3Reliability
If multiple intermediate clamps and connection structures are used, then electrical connection is established, but the device complexity increases
Solution Approach 1:
The patent merges the functions of intermediate clamps, connection terminals, and electrical connectors into a single integrated connection clamp. The connection clamp combines the electrical conducting function, the mechanical connection function, and the mounting function into one component that is directly inserted into the circuit board, significantly reducing the number of parts compared to traditional multi-component connection structures.
Solution Approach 2:
The connection clamp is designed as a universal component that performs multiple functions: it provides electrical connection through its conducting body, mechanical attachment through its insertion end, and structural support through its body. This multi-functional design eliminates the need for separate intermediate clamps, terminals, and connectors, reducing device complexity while maintaining reliable electrical connection.
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 approach reduces production complexity and costs by enabling a straightforward, compact connection design that simplifies the mounting process and ensures secure electrical contact between the stator and circuit board.
Implementation Method 1
the insulation displacement contact elements arranged correspondingly with respect to the jumper wires cut through the insulation of the jumper wire, and the jumper wire is brought in electrical contact with the respective insulation displacement contact element
Data Source
AI summary
A stator for an electric motor, connected to a circuit board, comprising a stator housing in which several winding arrangements consisting of winding wires wound to form coils are arranged. Contact support receptacles are formed on the stator housing, in which, in each case, an insulation displacement contact element is introduced, which establishes an electrical contact between, in each case, a winding arrangement and a jumper wire on the circuit board.