Resin-Molded Stator Terminal Support to Prevent Potting Failures

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Solution Overview

Problem

The existing method of potting electrical connections between male and female terminals in resin-molded stators increases manufacturing costs and processes due to potential conduction failures from gaps.

Innovation Solution

A resin-molded stator design with a second surface contact portion on the male terminal, supported by the insulator wall, prevents orientation changes during resin molding, eliminating the need for potting and reducing manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If potting is conducted for the electrical connection portion between the male terminal and female terminal, then conduction failure is avoided, but manufacturing cost and process increase

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing cost and process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The insulator is designed with a built-in support structure (protrusion and groove) that pre-establishes mechanical support for the male terminal before resin molding occurs. This preliminary structural arrangement prevents the need for post-assembly potting operations while ensuring reliable electrical connections are maintained throughout the molding process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent extracts the support function from the resin molding process itself and incorporates it directly into the insulator structure. By integrating the support protrusion and groove mechanism into the insulator, the patent eliminates the need for separate potting operations while maintaining the reliability benefits that would have required such additional processing.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of manufacture

If the male terminal is allowed to move freely during resin molding, then manufacturing process is simplified, but orientation change occurs causing conduction failure

Engineering Contradiction:

Improvemolding process simplicityVSAvoidelectrical connection stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The support protrusion and groove act as an intermediary mechanical structure between the male terminal and the insulator body. This intermediary feature provides the necessary mechanical constraint to prevent orientation changes during resin molding, allowing the terminal to remain stable without requiring complex molding processes or additional support components.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If the insulator uses a one-directional wall structure, then manufacturing is simplified, but terminal support during molding becomes challenging

Engineering Contradiction:

Improveinsulator manufacturing simplicityVSAvoidterminal orientation control

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

While the insulator maintains its overall simple one-directional wall structure for ease of manufacturing, the patent introduces localized features (the support protrusion and corresponding groove) at specific positions. This local quality enhancement provides precise terminal support and orientation control exactly where needed during resin molding, without complicating the overall insulator manufacturing process.

Inventive Principle:

Principle #3Local quality

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 inhibits conduction failures and reduces manufacturing costs by stabilizing the male terminal connection without potting, ensuring reliable electrical connections.

Implementation Method 1

The male terminal connection portion is pressed against the female terminal connection portion by the spring portion

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentEP4213350B1Resin molded stator, outer rotor-type motor, blower device, and air conditioner

Publication Date: 2025.12.03 DAIKIN INDUSTRIES LTD

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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 (12), a male terminal (13), and an insulator (14). The female terminal (12) includes a female terminal connection portion (12a) and a spring portion (12b). The male terminal (13) includes a male terminal connection portion (13a), a wire connection portion (13b), and a second surface contact portion (13c). The insulator (14) accommodates the female terminal connection portion (12a), the spring portion (12b), and the male terminal connection portion (13a), and electrically connects the male terminal (13) to the female terminal (12). The second surface contact portion (13c) faces a second surface (14c2) of the insulator wall (14c).