Stator Insulator Integrating PCBA Mounting and Wire Guidance
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Solution Overview
Problem
Existing electric motor designs face challenges in achieving compactness and cost-effectiveness due to inadequate insulation, inaccurate positioning of printed circuit board assemblies (PCBAs), and random magnetic wiring layouts, which increase material and labor costs and complexity.
Innovation Solution
The development of an insulator for the stator assembly that provides insulation, supports and positions the PBA, guides magnetic wiring, and integrates multiple functions such as guiding cross-over wires and controlling bending radii, using liquid crystal polymer (LCP) with molded features like petals and pin-type anchoring protrusions to ensure precise alignment and efficient coil winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional insulators (conformal films, paper strips, tapes, molded slotliners) are used for stator insulation, then insulation function is provided, but no mechanical purpose is served and additional components are needed for PCBA mounting and wire guidance
Solution Approach 1:
The insulator is designed to perform multiple functions simultaneously: electrical insulation between stator and coils, mechanical support for PCBA mounting, and guidance for magnetic wiring. This multi-functional design eliminates the need for separate components for each function, reducing overall device complexity while maintaining all required capabilities.
Solution Approach 2:
The patent combines previously separate functions (insulation, PCBA mounting, wire guidance) into a single integrated insulator component. By merging these functions into one part, the design reduces the number of discrete components needed in the motor assembly.
2Manufacturing precision
If PCBA is mounted on motor housing, endcap, or bracket, then mounting is achieved, but accurate positioning with respect to stator windings is difficult and compactness is compromised
Solution Approach 1:
The PCBA mounting function is merged with the insulator component. The insulator includes integrated mounting features that directly position the PCBA on the stator assembly, eliminating the need for separate mounting structures and enabling more compact motor design while maintaining precise positioning.
Solution Approach 2:
The insulator serves as an intermediary component that facilitates both insulation and PCBA mounting. By incorporating mounting features into the insulator itself, the design achieves accurate PCBA positioning relative to the stator windings without requiring additional mounting hardware.
3Ease of manufacture
If magnetic wiring is laid randomly without guidance, then assembly is simpler, but coil volume increases, resistance increases, and coil integrity decreases
Solution Approach 1:
The insulator includes pre-formed guide features (such as grooves or channels) that are built into the component during manufacturing. These guide features preliminarily establish the correct wire lay path, ensuring that magnetic wiring is properly guided during assembly without requiring complex external guidance mechanisms, thus maintaining both ease of manufacture and coil integrity.
Data Source
AI summary
An insulator for a stator assembly includes at least a first insulator adapted to be mounted to the stator core and structured to insulate the stator core from the coils. The at least one insulator includes structure to perform at least one additional function. For example, the structure may include a support member to support and/or locate the PCBA on the stator core, a wire guide to guide cross-over wires that form a connection between coils, and/or positioning structure to precisely position the PCBA with respect to the coils.