Stator Winding PCB Connector Using Dual Insulation Displacement Contacts
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Solution Overview
Problem
Existing electric motor connectors for stator windings to printed circuit boards are complex and have limited service life, requiring multiple connections that occupy space and are prone to reliability issues under aging and vibration.
Innovation Solution
A connector design using two insulation displacement contacts with clamping slots and a single press-fit contact, allowing for compact, reliable, and long-lasting electrical connections by combining winding wire ends into a single connection, enabling increased wire diameter for higher current capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If multiple separate electrical connections are used for winding wire ends to the printed circuit board, then each connection can be individually optimized, but the overall device complexity increases and more space is occupied
Solution Approach 1:
The patent combines multiple electrical connections into a single integrated connector body that houses multiple insulation displacement contacts. This merging approach reduces the number of separate connectors needed and consolidates the electrical connections to the printed circuit board, thereby reducing overall device complexity and occupying less space while maintaining individual contact optimization
2Reliability
If conventional welded or soldered connections are used, then electrical connection is achieved, but the service life is limited and reliability decreases under aging and vibration
Solution Approach 1:
The patent replaces conventional welded or soldered mechanical connections with insulation displacement contacts that establish electrical connection through mechanical insertion and contact pressure. This substitution eliminates the thermal processes and potential weaknesses of welding/soldering, providing connections that are more resistant to aging and vibration while maintaining long service life
Solution Approach 2:
The insulation displacement contacts are pre-configured with clamping slots and contact elements that automatically establish reliable electrical connection upon insertion of the winding wire ends. This preliminary preparation of the connection structure ensures immediate and durable contact without requiring additional assembly steps or thermal processes, enhancing both reliability and service life
3Quantity of substance
If insulation between contacts is required, then electrical isolation is achieved, but the wire diameter must be smaller and current carrying capacity is reduced
Solution Approach 1:
The connector body is segmented into separate contact regions with physically isolated clamping slots for each contact. This segmentation provides inherent electrical isolation between contacts through the insulating connector material itself, eliminating the need for additional insulation measures around individual contacts and allowing larger wire diameters to be used without compromising electrical isolation
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
The solution provides a compact, reliable, and durable electrical connection that maintains contact reliability even under aging and vibration, while allowing for increased current carrying capacity per motor phase without the need for insulation between contacts.
Implementation Method 1
at least two legs being resilient
Data Source
AI summary
An electric motor includes a rotor and a stator including a stator core and coils. The coils are defined by a winding wire including winding wire ends electrically contacted with a printed circuit board at an end surface through connectors. The connectors each include at least two insulation displacement contacts receiving a winding wire end of a stator winding. Each connector includes a single electrical connection to the printed circuit board. The connector includes a base body with an underside in contact with the printed circuit board. Each of the at least two insulation displacement contacts includes a clamping slot perpendicular to the underside of the base body. The clamping slots are defined by spaced legs extending from the base body, at least two of the spaced legs being resilient.