Detachable Stator Lead Wire Guide for Moisture Resistance
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Solution Overview
Problem
Conventional molded electric motor stators face increased costs due to heat shrinkable tubes with adhesive layers for winding connections and are prone to moisture ingress along the interface between lead wire leading components and molding resin, which can compromise the sensor substrate.
Innovation Solution
A stator design where the lead wire leading component is detachable from the lead wire wiring component before molding, using a lead wire guide and projection portions to facilitate assembly and separation, preventing moisture ingress and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the lead wire leading component is assembled directly to the sensor substrate with contact to the stator core, then the assembly is simplified, but moisture can enter along the interface of the leading component compromising the sensor substrate
Solution Approach 1:
The patent segments the lead wire leading component from the sensor substrate by introducing a resin portion that physically separates them. The leading component is assembled to the stator core first, then the resin portion is molded to cover and isolate it from the sensor substrate, creating distinct functional zones that prevent moisture migration while maintaining assembly simplicity.
Solution Approach 2:
The resin portion acts as an intermediary barrier between the lead wire leading component and the sensor substrate. This intermediate layer prevents direct contact and blocks moisture pathways, allowing both components to coexist in the assembly without compromising reliability.
2Reliability
If heat shrinkable tube with adhesive layer is used to cover winding connections, then connection reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges the protective function previously requiring separate heat shrinkable tubes with the molding resin that is already applied to the stator. The resin portion is molded to directly cover the winding connections and lead wire leading component, integrating the protective function into an existing manufacturing step and eliminating the need for additional heat shrinkable tubes and adhesive layers.
Solution Approach 2:
The patent extracts the protective function from the expensive heat shrinkable tube assembly and transfers it to the molding resin. By removing the unnecessary heat shrinkable tube and adhesive layer while maintaining the protective coverage through the resin portion, manufacturing cost is reduced while connection reliability is preserved.
Data Source
AI summary
A lead wire wiring component includes a lead wire guide that guides power supply lead wires and sensor lead wires to a lead wire leading component. The lead wire leading component includes projection portions that can be assembled to the lead wire guide. The projection portions are detached from the lead wire guide for molding such that the lead wire leading component is detached from the lead wire wiring component during the molding.