Stator Contact Ring with Conductive Bore Connections
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Solution Overview
Problem
Existing electric motor stators face challenges in achieving a compact, reliable, and efficient electrical supply to coil windings due to complex wiring and insulation issues, which affect their operational simplicity and weight.
Innovation Solution
The stator design incorporates integrally formed or separately produced lines connected via a contact ring with an insulating sleeve, where the lines and contact ring are molded with plastic to create a cohesive, compact, and reliable electrical supply system, utilizing conducting means like tin or conductive adhesives for connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional separate wiring and insulation methods are used for coil windings, then electrical connections can be established, but the stator becomes more complex and heavier
Solution Approach 1:
The patent merges the conductor, insulating sheath, and connection elements into a single integrated component. The conductor is directly encased in an insulating sheath that extends to form the connection, eliminating the need for separate wiring and insulation steps. This integration reduces device complexity while maintaining reliable electrical connections.
Solution Approach 2:
The patent uses composite construction by combining conductive material (copper or aluminum) with insulating material (plastic sheath) into a single integrated component. The conductor and insulating sheath are manufactured together as one piece, creating a composite structure that simplifies the overall wiring system while ensuring reliable electrical connections with proper insulation.
2Weight of moving object
If traditional wiring methods are used, then electrical connections can be made, but the stator weight increases
Solution Approach 1:
The patent combines multiple separate components (conductor, insulating material, connection elements) into a single integrated wiring component manufactured in one process. This elimination of separate parts directly reduces the overall weight of the stator while the integrated design actually simplifies manufacturing by reducing assembly steps.
3Ease of manufacture
If conductors are not encased in insulating sheath, then manufacturing is simpler, but electrical insulation is compromised
Solution Approach 1:
The insulating sheath is integrated directly onto the conductor during manufacturing, forming a single unified component. The sheath is molded or extruded directly over the conductor in one continuous process, ensuring proper electrical insulation is maintained while keeping the manufacturing process simple and efficient.
4Reliability
If contact ring connections are not integrated, then assembly is easier, but connection reliability decreases
Solution Approach 1:
The connection element is integrated directly into the contact ring structure, eliminating separate connection components. The insulating sheath of the conductor is directly formed to connect with the contact ring in a unified structure, ensuring reliable electrical and mechanical connections while the integrated design actually reduces overall device complexity.
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 results in a more compact, reliable, and efficient electrical supply to the coil windings, improving the stator's operational behavior, weight, and manufacturing process, while ensuring a low-resistance and assembly-friendly connection.
Implementation Method 1
filled with conductive materials that electrically connect the conductors and the terminals
Implementation Method 2
The conductors are at least partially encased in an insulating sheath, which in a further development may consist of plastic
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to a stator for an electric motor, wherein the stator has a plurality of lines (51) for the electrical supply of coil windings (50) of the stator and a contact ring with, in particular at least partially sheathed with an insulating sleeve, terminals (14, 24, 34) for the electrical supply of these lines, wherein these terminals are at least partially formed in a contact ring body (40) and this contact ring body has bores (70) which intersect or cut through the terminals, in particular their insulating sleeve, and are at least partially filled with conductive means (71), wherein these conductive means electrically connect the lines and the terminals.