Stator Unit Moisture Seal via Integrated Washer
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Solution Overview
Problem
Existing stator units for electric motors, particularly external rotor motors, face issues with moisture penetration through passage openings and fastening holes, leading to potential damage of motor electronics due to inadequate sealing within the housing flange.
Innovation Solution
A sealing washer with elastic plastic sealing areas is placed between the stator and housing flange, forming a central contact section that directly or indirectly seals the passage openings and fastening holes, eliminating the need for individual seals and allowing for pre-assembly and cost-effective production as a two-component injection-molded part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a seal is placed inside the housing only, then the housing structure is simple, but moisture can penetrate through passage openings and fastening holes into the housing
Solution Approach 1:
The patent combines multiple sealing functions into a single sealing washer component that seals around the motor connection contacts, fasteners, and passage openings simultaneously. This merging of sealing functions resolves the contradiction by providing comprehensive moisture protection without requiring multiple separate seals, thus maintaining structural simplicity while improving reliability
Solution Approach 2:
The sealing washer acts as an intermediary element between the stator and housing flange, creating a barrier that prevents moisture penetration through the passage openings and fastening holes. This intermediary component resolves the contradiction by providing effective sealing without complicating the overall housing structure
2Reliability
If individual seals are used for each passage opening and fastening hole, then sealing effectiveness is high, but the number of components and assembly complexity increases
Solution Approach 1:
The patent merges the function of multiple individual seals into a single integrated sealing washer that provides sealing for all passage openings and fastening holes simultaneously. This resolves the contradiction by maintaining high sealing effectiveness through the continuous sealing surface while reducing the number of components from multiple individual seals to one unified element
Solution Approach 2:
The sealing washer is designed as a universal sealing component that performs multiple sealing functions at once - sealing around motor connection contacts, fasteners, and passage openings. This multi-functionality resolves the contradiction by providing comprehensive sealing coverage without requiring separate specialized seals for each opening
3Ease of manufacture
If multiple individual sealing elements are produced and assembled, then each seal can be optimized for its specific opening, but production costs and assembly time increase
Solution Approach 1:
The patent combines multiple sealing functions into a single sealing washer that is produced as one integrated component. This resolves the contradiction by reducing production costs through single-component manufacturing while maintaining precise sealing fits through the carefully designed geometry of the sealing surfaces that conform to the specific openings
4Reliability
If passage openings and fastening holes are sealed separately, then each opening is properly sealed, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent merges all sealing operations into a single step by using one sealing washer that seals all passage openings and fastening holes simultaneously during one assembly operation. This resolves the contradiction by ensuring complete sealing coverage while dramatically improving assembly speed and productivity
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
The solution effectively prevents moisture ingress, achieving a high IP protection class (IP69K) by creating sealed chambers around the openings, ensuring the motor electronics remain dry and protected from dust and high-pressure steam jets.
Implementation Method 1
the sealing washer has sealing areas made of elastic plastic, which are arranged and designed in such a way that there is a direct and/or indirect sealing of the passage openings and/or the fastening holes against the passage of moisture
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention relates to a stator unit for an electric motor, in particular an external rotor motor. The stator unit consists of a stator (1) with a stator lamination stack (2) and stator windings (4), a stator bushing (3), and a stator flange (9) with a single end. A housing flange (12) of a housing (11) for receiving a motor controller or the like is attached to the stator flange (9), as are motor connection contacts (21) extending from the stator (1) through through-holes in the housing flange (12) and fastening means extending through mounting holes in the housing flange (12) and secured in the stator (1). A sealing washer (31) is arranged between the stator (1) and the housing flange (12).The sealing disc has sealing areas made of elastic plastic, which are arranged and designed in such a way as to provide a direct and/or indirect seal of the penetration openings and/or the mounting holes against moisture penetration.