Motor Stator Terminal Pin Shielding During Injection Molding
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Solution Overview
Problem
During the injection molding of motor housings, the injection material often penetrates into the gap between the terminal pin of the stator and the mold, causing damage to the terminal pin and compromising the electrical connection with the PCB, leading to poor conductivity and increased production costs.
Innovation Solution
The design incorporates a terminal pin accommodating portion with a protruding terminal pin supporting structure that shields the gap from the injection material, using a bent terminal pin configuration where one side protrudes through a through hole in the accommodating portion and another side through a hole in the supporting portion, ensuring the terminal pin is securely positioned and protected during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the terminal pin is directly exposed during injection molding, then the manufacturing process is simple, but the injection material penetrates into the gap between the terminal pin and mold causing damage and poor conductivity
Solution Approach 1:
The patent introduces a terminal pin accommodating portion as an intermediary structure that mediates between the terminal pin and the injection mold. This accommodating portion provides a protective interface that prevents direct contact between the injection material and the terminal pin, thereby maintaining electrical connection reliability while allowing the manufacturing process to proceed
2Reliability
If the terminal pin is protected from injection material, then electrical connection reliability is maintained, but the device structure becomes more complex
Solution Approach 1:
The patent merges the terminal pin accommodating portion with the insulator structure, integrating the protective function into an existing component rather than adding a separate protective device. This integration maintains electrical connection reliability while minimizing the increase in device complexity by combining multiple functions into a unified structure
3Object-affected harmful factors
If the terminal pin accommodating portion protrudes to shield the gap, then injection material penetration is prevented, but the manufacturing precision requirements increase
Solution Approach 1:
The patent implements preliminary action by pre-positioning the terminal pin within the terminal pin accommodating portion before the injection molding process begins. The accommodating portion is designed with predetermined dimensions and positioning features that guide the terminal pin into the correct position, thereby preventing injection material penetration while managing manufacturing precision requirements through advance preparation
Data Source
AI summary
A motor that includes a stator having an improved structure is provided. The motor includes a stator that includes stator cores wound with a coil, a rotor disposed in the stator and configured to interact with the stator and to rotate, a shaft mounted on the rotor and configured to rotate with the rotor, a printed circuit board (PCB) electrically connected to the coil, an insulator formed of an insulating material and mounted on the stator, and a terminal pin mounted on the insulator to connect the coil with the PCB. A terminal pin accommodating portion that protrudes in an extension direction of the shaft is provided in one side of the insulator and the terminal pin is accommodated in the terminal pin accommodating portion.