Stator Wire Overmolding Cavity Connection
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Solution Overview
Problem
Existing methods for electrically connecting a stator's wire element to a contact ring or printed circuit board require numerous intermediate steps and components, leading to a bulky design unsuitable for small applications.
Innovation Solution
Direct placement of the contact ring or printed circuit board on the stator with overmolding to create cavities for electrical connection, using conductive material to establish contact and minimize space, potentially eliminating the need for intermediate components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wiring methods with intermediate components (contact rings, adapters) are used to electrically connect wire elements to carrier elements, then reliable electrical contact is achieved, but the device complexity and volume increase significantly
Solution Approach 1:
The patent merges the wire element directly with the carrier element by integrating the electrical connection into the molding process. The wire element is positioned in a recess of the carrier element, and molding material is injected to surround and electrically connect the wire to the carrier element, eliminating the need for separate contact rings, adapters, or other intermediate components. This merging reduces device complexity while maintaining reliable electrical contact through the integrated molding structure.
2Reliability
If traditional wiring methods with multiple intermediate components are used, then electrical connection is established, but the overall volume of the stator assembly increases making it unsuitable for small designs
Solution Approach 1:
The patent applies nesting by placing the wire element within a recess of the carrier element, and then surrounding it with molding material that fills the space efficiently. The wire element is nested within the carrier element's recess, and the molding material is nested around the wire element, creating a compact integrated structure. This nested arrangement minimizes the overall volume of the stator assembly while ensuring reliable electrical connection, making it suitable for small-scale applications.
3Reliability
If traditional wiring methods with multiple steps and intermediate components are used, then electrical contact is achieved, but the manufacturing process requires many intermediate steps increasing production time and cost
Solution Approach 1:
The patent applies preliminary action by pre-positioning the wire element in the recess of the carrier element before the molding process. The wire element is arranged in the desired position and orientation in advance, and then the molding material is injected to complete the electrical connection in a single integrated step. This preliminary positioning eliminates the need for multiple separate assembly steps, such as separately installing contact rings, adapters, or making separate electrical connections, thereby significantly improving manufacturing efficiency and productivity while ensuring reliable electrical contact.
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 approach reduces the number of steps and components, resulting in a compact stator design suitable for small electrical machines, with flexible production and reduced costs.
Implementation Method 1
The cavity duct is at least partially filled with an electrically conductive material. The at least one connection hole forms together with a corresponding cavity a cavity duct. According to the invention, each cavity duct is at least partially filled with an electrically conductive material. The electrical contact between the at least one electric component of the carrier element and the wire element in the at least one predetermined section is established.
Data Source
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AI summary
The invention is concerned with a method for electrically connecting a wire element (14) of a stator (10) with a carrier element (26). The invention is characterized in that the wire element (14) and the stator (10) are covered by an overmolding (18), wherein at least one cavity (22) is drilled through the overmolding (18) and through the wire element (14) of the stator (10) such that the wire element (14) is at least partially disrupted in at least one predetermined section (17) . The carrier element (26) is positioned on the overmolding (18) of the stator (10) such that a connection hole (30) of the carrier element (26) aligns with one cavity (22). The cavity (22) and the connection hole (30) are at least partially filled with an electrically conductive material (34). In sum an electrical contact is established between the carrier element (26) and the wire element (14).