Stator Insulator Guide Structure to Prevent Coil Exposure
Solution Overview
Problem
The existing manufacturing process for motors, particularly the stator, faces challenges in preventing coil exposure during over-molding, which can lead to short circuits and increased production costs due to the need for additional forming processes.
Innovation Solution
A stator design featuring a stator core with a yoke and teeth, an insulator with specific guides and protrusions to prevent coil exposure, and a molding portion that covers the core, insulator, and coil, using an injection method to inhibit coil exposure during over-molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If secondary injection is performed to form the coil, then the coil can be wound around the insulator, but the coil may be exposed by injection molding pressure causing short circuit risk
Solution Approach 1:
The patent applies preliminary action by forming the insulator with protrusions that extend into the coil windings before the secondary injection process. These protrusions are pre-positioned to penetrate and secure the coil windings, preventing coil exposure during subsequent molding operations. This preliminary structural preparation eliminates the need for additional forming processes while maintaining coil security and preventing short circuits.
Solution Approach 2:
The patent applies local quality by creating localized protrusions at specific positions on the insulator where coil windings need to be secured. Rather than modifying the entire insulator structure, the protrusions are strategically placed only where needed to penetrate and hold the coil windings, providing targeted reinforcement exactly where the coil exposure risk exists during injection molding.
2Reliability
If a forming process is added to inhibit coil exposure, then short circuit risk is reduced, but production cost increases
Solution Approach 1:
The patent merges the coil-securing function with the insulator structure itself by integrating protrusions directly into the insulator body. This combination eliminates the need for separate forming processes that would otherwise be required to secure the coil, as the insulator simultaneously provides both insulation and mechanical retention of the coil windings through its protrusions.
Solution Approach 2:
The patent applies self-service by designing the insulator to automatically secure the coil windings through its own protrusions during the normal injection molding process. The protrusions self-penetrate and self-position into the coil windings without requiring external intervention or additional forming steps, making the coil-securing function inherent to the insulator structure itself.
3Ease of manufacture
If the insulator structure is simplified, then manufacturing is easier, but coil exposure during over-molding cannot be prevented
Solution Approach 1:
The patent applies segmentation by dividing the insulator into functional zones: a body portion for insulation and multiple protrusions for coil securing. This segmentation allows the insulator to maintain a relatively simple overall structure while incorporating localized features (protrusions) that provide precise coil positioning. The protrusions act as discrete elements that can be formed using standard injection molding techniques without requiring complex tooling or multi-step processes.
Data Source
AI summary
An embodiment relates to a stator and a motor comprising same, the stator comprising: a stator core comprising a yoke and multiple teeth protruding from the inner surface of the yoke; an insulator surrounding a part of the stator core; a coil wound around the insulator; and a molding portion disposed to cover the stator core, the insulator, and the coil. The insulator comprises a first insulator and a second insulator. The first insulator comprises: a body portion around which the coil is wound; and inner guide extending from the inside of the body portion in the perpendicular direction; a first outer guide extending from the outside of the body portion in the perpendicular direction; a second outer guide disposed to be spaced apart from the first outer guide in the outward direction; and a protrusion protruding from the second outer guide in the inward direction. The protrusion has an end portion disposed such that a predetermined gap (G) is formed between same and the first outer guide. The coil has a part disposed between the first outer guide and the second outer guide through the gap (G). Accordingly, it is possible to inhibit the coil from contacting the housing due to injection molding pressure during over-molding of the stator.