Injection-Molded Stator Sealing for Controller Lead-Throughs
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Solution Overview
Problem
Existing stator components in electrodynamic machines face challenges in hermetically sealing metallic conductor elements to prevent aggressive media from reaching the electronic controller, particularly in applications with high vibrations and thermal shocks, leading to potential damage and detachment issues.
Innovation Solution
The stator component features a thermoplastic plastic structure with embedded conductor elements, a freely projecting cuff surrounding the conductor elements, and laser-engraved grooves for enhanced adhesion, eliminating the need for separate sealing materials, and allowing for deformation to accommodate thermal and mechanical stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the plastic structure is constructed as a bowl with conductor elements led out for contacting the electronic controller, then the electronic controller can be accessed, but the risk of medium creeping along the conductor element surface to the controller increases
Solution Approach 1:
A sealing element is introduced as an intermediary component between the conductor element and the plastic structure. This sealing element extends along the conductor element and prevents medium from creeping along the conductor element surface to the electronic controller, while still allowing the conductor element to pass through for electrical connection.
2Reliability
If a sealing compound is used to fill the bowl structure for hermetic sealing, then the electronic controller is protected from medium, but the manufacturing effort and complexity increase considerably
Solution Approach 1:
The sealing function is extracted from the plastic structure itself and implemented as a separate sealing element. This allows the plastic structure to be produced by standard injection molding without complex bowl-shaped cavities and sealing compound filling operations, significantly simplifying manufacturing while maintaining hermetic sealing capability.
3Reliability
If thermoset material is used for the plastic structure to improve adhesion to conductor elements, then sealing performance improves, but processing restrictions and material choices are significantly limited
Solution Approach 1:
The system is segmented into distinct functional components: the plastic structure provides mechanical support and mounting, while the separate sealing element provides the adhesion and sealing function. This segmentation allows each component to be optimized independently, enabling the use of thermoplastic materials with broad processing flexibility and material choices while maintaining reliable sealing performance.
4Reliability
If the plastic structure is rigidly fixed to prevent detachment, then sealing reliability improves, but the structure cannot accommodate thermal expansion and vibration stresses
Solution Approach 1:
The sealing element is designed with dynamic characteristics that allow it to flex and deform in response to thermal expansion and vibration stresses. This dynamic sealing element maintains contact with the conductor element while accommodating dimensional changes, preventing detachment while preserving sealing reliability under varying operating conditions.
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 provides durable sealing, reduces detachment tendencies, and meets stringent automotive industry test procedures by preventing media ingress and protecting the electronic controller, while allowing for broad material choices and flexible construction.
Implementation Method 1
fine structurings in the form of grooves machined by means of laser engraving into the surface and filled with thermoplastic of the plastic structure are provided, all around the respective circumference, in the portions of the metallic conductor elements that penetrate the respective cuff
Data Source
AI summary
A stator component of an electrodynamic machine is provided, having a plastic structure, a stator unit at least partly integrated into the plastic structure and having coil windings, an electronic controller, and multiple metal conductor elements, by which the windings connect to the controller. A part of the extension of the conductor elements is integrated into the plastic structure. The plastic structure is produced by injection molding onto a preassembled group including the stator unit and conductor elements connected to the coil windings. The plastic structure forms a collar adjacent each conductor element free end section which projects from the plastic structure and is paired with the contact of the controller, said collar surrounding the circumference of the conductor element and protruding beyond the rest of the plastic structure. The sections of the conductor elements passing through each collar have grooves filled with thermoplastic ribs of the plastic structure.