Stator Resin Vent Channel Reservoir Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing stator sealing methods with resin materials face challenges in preventing resin flow through vent channels without complicating the mold structure, and resin leaks can contaminate equipment with glass fibers, leading to potential failures.
Innovation Solution
The stator design incorporates a terminal block with a vent channel and a resin reservoir formed by expanding the cross-section of the vent channel, which captures resin material and reorients glass fibers to prevent leakage, eliminating the need for complex mold configurations and minimizing glass fiber contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an air vent is formed in the mold to discharge air from the cavity, then air discharge efficiency is improved, but the mold structure becomes complicated due to the need for opening and closing mechanisms to prevent resin leakage
Solution Approach 1:
The invention extracts the vent channel from the mold structure and relocates it to the terminal block. The terminal block now serves dual purposes: electrical connection and air venting. This eliminates the need for complex opening and closing mechanisms in the mold while maintaining effective air discharge, as the vent channel is permanently integrated into the terminal block structure.
Solution Approach 2:
The terminal block is given multiple functions: it serves as both an electrical connection component and an air venting structure. By integrating the vent channel into the terminal block, the invention eliminates the need for separate mold venting mechanisms, thereby simplifying the overall mold structure while maintaining air discharge efficiency.
2Device complexity
If the mold structure is simplified by removing opening and closing mechanisms, then device complexity is reduced, but resin material may flow through the vent channel to the outside
Solution Approach 1:
The vent channel cross-section is designed with non-uniform properties along its length. The cross-sectional area increases from the cavity side toward the terminal block exterior, creating a gradual expansion. This local variation in geometry causes resin to slow down and pool in the expansion region, preventing it from reaching the exterior while still allowing air to escape.
Solution Approach 2:
The vent channel geometry is pre-designed with an expanding cross-section that automatically captures resin before it can reach the exterior. This preliminary geometric configuration ensures that resin is trapped in the expansion region during the molding process, preventing leakage without requiring active control mechanisms.
3Reliability
If resin material flows through the vent channel to the outside, then air discharge is effective, but glass fibers in the resin contaminate equipment and cause failures
Solution Approach 1:
The vent channel cross-sectional area varies along its length, creating a localized expansion region. This geometric variation causes resin and embedded glass fibers to slow down and pool in the expansion area, preventing them from reaching the exterior and causing contamination, while still maintaining effective air discharge capability.
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
This design effectively prevents resin from flowing outside the stator without adding complexity to the mold structure and reduces the risk of glass fiber contamination, ensuring reliable resin capture and preventing equipment failures due to resin leaks.
Implementation Method 1
a resin reservoir that is formed by partially expanding a cross-section of the vent channel
Implementation Method 2
the resin reservoir expands in a direction of a channel depth of the vent channel... it is possible to reliably cause the Barus effect to occur inside the vent channel and change the orientation of the glass fibers to upward in the resin reservoir
Data Source
AI summary
At the time of molding, in the stator, the resin material flows inside the vent channels that are formed on the terminal block. At this time, as the resin reservoirs which are formed by expanding cross-sections of the vent channels are provided on the mounting surface of the terminal block, the resin material can be retained in the resin reservoirs. This consequently prevents the resin material from flowing through the vent channels to the outside of the terminal block. When the resin leaked part, which is the resin material that has leaked from the vent channels to the outside and been hardened, falls while using the motor, there is an adverse effect on another piece of equipment. Thus, the resin reservoirs that are formed in the vent channels act effectively in terms of preventing the resin material from flowing to the outside.