Resin-Molded Stator Terminal Structure Without Potting Gaps
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing resin-molded stators face conduction failures due to gaps between male and female terminals, which are costly to address through potting, increasing manufacturing complexity.
Innovation Solution
A resin-molded stator design featuring a female terminal with a spring portion and a male terminal with a second surface contact portion, where the insulator wall is sandwiched between the male terminal connection and the second surface contact, preventing orientation changes during resin molding without the need for potting, thus ensuring electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If potting is applied to bond male and female terminals to avoid conduction failures, then reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts the problematic gap between male and female terminals by introducing an insulator with an accommodation portion that houses the female terminal connection portion. This eliminates the need for potting while maintaining reliable electrical connection, as the insulator structurally prevents gap formation without requiring additional bonding materials or complex manufacturing processes
Solution Approach 2:
The insulator acts as an intermediary component that mediates between the male and female terminals. The accommodation portion of the insulator provides a structured interface that ensures proper alignment and contact between terminals, achieving reliable electrical connection through structural design rather than through potting or bonding processes
2Reliability
If the male terminal connection portion is pressed against the female terminal connection portion by the spring portion, then electrical connection reliability is improved, but the risk of orientation change during resin molding increases
Solution Approach 1:
The spring portion is pre-configured within the female terminal connection portion to provide preliminary pressing force on the male terminal connection portion. This preliminary action ensures electrical contact is established before resin molding begins, and the insulator's accommodation portion maintains this orientation stability throughout the molding process without requiring additional constraints
Solution Approach 2:
The patent addresses the orientation stability issue by moving the constraint mechanism from the horizontal plane (where terminal pressing occurs) to the vertical dimension through the insulator's accommodation portion. The insulator wall extends in the vertical direction to provide structural support that prevents orientation changes during resin molding, separating the electrical connection function from the orientation constraint function
Data Source
AI summary
In resin molding, potting to be conducted with a male terminal bonded to a female terminal increases costs and processes. A resin-molded stator includes a coil, a female terminal, a male terminal, and an insulator. The female terminal includes a female terminal connection portion and a spring portion. The male terminal includes a male terminal connection portion, a wire connection portion, and a second surface contact portion. The insulator accommodates the female terminal connection portion, the spring portion, and the male terminal connection portion, and electrically connects the male terminal to the female terminal. The second surface contact portion faces a second surface of the insulator wall.