Motor Stator Insulator Extension for Resin Molding Deformation
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Solution Overview
Problem
Existing stator designs for motors sealed with resin face deformation issues during resin molding, leading to increased manufacturing costs due to the need for additional reinforcing members and modified molds.
Innovation Solution
Incorporating an extension portion on the insulator that extends towards the terminals, with a cut-out hole in the sealing member to be supported by pins in the mold, allowing the insulator to be supported without additional parts or mold changes, thereby suppressing deformation and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a reinforcing member is added to the insulator to suppress deformation during resin molding, then the deformation suppression is improved, but the number of parts increases
Solution Approach 1:
The reinforcing function is merged into the insulator itself by adding an extension portion that integrates with the insulator structure. This eliminates the need for a separate reinforcing member while maintaining the deformation suppression function during resin molding.
Solution Approach 2:
The insulator serves dual functions: its original insulating function and the additional function of suppressing deformation through its extension portion. The extension portion acts as a self-reinforcing structure that eliminates the need for external reinforcing components.
2Manufacturing precision
If a protrusion portion is added to the mold to support the insulator during resin molding, then the deformation suppression is improved, but the mold complexity increases
Solution Approach 1:
Instead of modifying the mold to add support structures, the solution inverts the approach by modifying the insulator itself to provide the necessary support interface. The extension portion of the insulator contacts the mold directly, eliminating the need for protrusion portions in the mold.
Solution Approach 2:
The insulator's extension portion serves as its own support structure during molding, eliminating the need for external mold modifications. The insulator itself provides the interface for mold contact and support.
3Manufacturing precision
If additional reinforcing structures are added to the insulator, then the deformation suppression is improved, but the manufacturing cost increases
Solution Approach 1:
The reinforcing function is combined with the insulator in a single integrated structure. The extension portion is formed as part of the insulator manufacturing process, eliminating the need for separate reinforcing components and reducing overall manufacturing cost.
Solution Approach 2:
The insulator is designed to perform multiple functions: electrical insulation and structural support during molding. The extension portion adds support capability without requiring separate components, reducing total part count and manufacturing complexity.
Data Source
AI summary
An insulator constituting a stator for a motor includes an extension portion that extends from a portion of a circumferential wall portion toward a plurality of terminals conforming to an axis line of the stator. A sealing member includes a cut-out hole in between an adjacent pair of the plurality of terminals, the cut-out hole being a through-hole extending conforming to the axis line. An end of the cut-out hole is blocked by an end surface of the extension portion.