Terminal element, motor winding structure and method for manufacturing motor winding structure

A terminal element, a motor winding structure and a manufacturing method are disclosed. The terminal element includes a fixing portion, a positioning portion and a buffering portion. The fixing portion is disposed at one end of the terminal element and has a serrate fixing pattern. The fixing portion is connected with a connecting position of the motor winding bobbin. The positioning portion is disposed adjacent to the fixing portion and urged against the motor winding structure for positioning the fixing portion while it is connected with the connecting position. The buffering portion has a first bending and a second bending, and the first bending is connected to positioning portion. The buffering portion absorbs the force applied to the terminal element.

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates to a terminal element, a motor winding structure and a manufacturing method and, in particular, to a terminal element capable of firmly connecting with a motor winding bobbin to form a motor winding structure.

2. Related Art

The connecting methods between components of an electronic device and terminals are optional depending on the materials and applications. For example, the connection of metals is usually done by soldering. The connection of plastic components is usually done by melting or via an adhesive. In addition, the connection between the plastic component and metal terminal is also common in motors and its output terminals.

As shown inFIG. 1AandFIG. 1B, a conventional terminal element1is inserted to a connecting end21of a motor winding bobbin2. The connecting end21is made by plastic, and the terminal element1is made by metal. The terminal element1has an end11with a round, smooth surface. The connection between the terminal element1and the winding bobbin2is done by inserting the end11into the connecting end21so as to fix the end11in the connecting end21.

However, when the terminal element1is inserted into the connecting end21, the precision of inserting position is completely controlled by tools or machines. Each of the terminal element1and the winding bobbin2has its material tolerance. Therefore, inserting position of the terminal element1into the winding bobbin2cannot be accurately controlled. This may result in damages to the winding bobbin2, thereby making the terminal structure loose, increasing the production cost and reducing the product reliability. For example, when the insertion of the terminal element1into the winding structure2is not deep enough, the terminal element1is likely to depart from the winding structure because of insufficient support. On the other hand, if the insertion of the terminal element1into the winding bobbin2is too deep, the winding bobbin2may be pierced through by the terminal element1and thus broken, as shown inFIG. 1A.

Moreover, the winding bobbin2is electrically connected with an external system via the terminal element1. Therefore, the terminal element1is pushed or pulled by an external force when the winding bobbin2is combined with or departed from the external system. Since the connection between the terminal element1and the winding bobbin2is merely a tight contact, the connecting force therebetween is fairly weak. Once the above-mentioned external force is imposed on the terminal element1, the terminal element1is pushed inward to damage the winding bobbin2or pulled away from the winding bobbin2.

As mentioned above, it is an important subjective to provide a terminal element, a motor winding structure and a manufacturing method for motor winding structure, which can prevent damages to the winding bobbin, and enhance connecting strength between the terminal element and the motor winding bobbin.

SUMMARY OF THE INVENTION

In view of the foregoing, the present invention is to provide a terminal element, a motor winding structure and a manufacturing method capable of increasing the connecting strength between the terminal element and a motor winding bobbin to form the motor winding structure, thereby preventing loose connections or departure, ensuring the product reliability, simplifying the man manufacturing process, and decreasing the cost.

In addition, the present invention is also to provide a terminal element that efficiently buffers improper actions imposed on the motor winding structure to ensure the product reliability.

To achieve the above, the present invention discloses a terminal element including a fixing portion, a positioning portion and a buffering portion. The fixing portion has a serrate fixing pattern and is disposed on one end of the terminal element for connecting with a connecting position of an electronic device, such as a motor winding bobbin. The positioning portion is disposed adjacent to the fixing portion to urge against the electronic device, thereby positioning the fixing portion to the connecting position of the electronic device. The buffering portion has a first bending and a second bending, and the first bending is connected to the positioning portion. The buffering portion absorbs the force applied to the terminal element.

In the terminal element of the present invention, the serrate fixing pattern is an irregular pattern. The serrate fixing pattern is formed around an axial direction of the fixing portion, or the serrate fixing pattern is formed on only one side of the fixing portion.

In addition, the present invention further discloses a motor winding structure including a motor winding bobbin, a terminal element and a welding material. The motor winding bobbin has a connecting position. The terminal element includes a fixing portion, a positioning portion and a buffering portion. The fixing portion has a serrate fixing pattern and is disposed on one end of the terminal element for connecting with a connecting position of the motor winding bobbin. The positioning portion is disposed adjacent to the fixing portion to urge against the motor winding bobbin, thereby positioning the fixing portion to a connecting position of the motor winding bobbin. The buffering portion has a first bending and a second bending, and the first bending is connected to the positioning portion. The buffering portion absorbs the force applied to the terminal element. The welding material is to cover the positioning portion and the connecting position of the motor winding bobbin.

Furthermore, the present invention further discloses a manufacturing method for a motor winding structure including a connecting process, a positioning process and a welding process. The manufacturing method of the invention includes the following steps of: inserting a fixing portion of a terminal element into a connecting position of a motor winding bobbin; urging a positioning portion of the terminal element against the motor winding bobbin, wherein a buffering portion absorbs the external force applied to the terminal element; and covering the positioning portion of the terminal element and the connecting position of the motor winding bobbin by a welding material.

As mentioned above, the terminal element of the present invention has a serrate fixing pattern that can increase the connecting force between the terminal element and the electronic device so that the terminal element cannot be easily pulled away from the electronic device. Since the terminal element of the present invention has a positioning portion, the connecting depth of the terminal element in the connecting position of the electronic device can be accurately positioned. The buffering portion of the terminal element can greatly reduce the force applying on the contact portion between the terminal element and the connecting position of the electronic device. In addition, the terminal element and the motor winding bobbin are welded together by the welding material to increase the connecting force therebetween. The above-mentioned features of the present invention can prevent damages to the electronic device, increase the stability of the system, simplify the manufacturing process, and decrease the production cost.

DETAILED DESCRIPTION OF THE INVENTION

As shown inFIG. 2, a motor winding structure3according to a preferred embodiment of the present invention includes a terminal element4, an electronic device and a welding material6.

The terminal element4has a fixing portion41, a positioning portion42and a buffering portion43. The terminal element4can be integrally formed. More explicitly, the fixing portion41, the positioning portion42and the buffering portion43are integrally formed as a single unit. In this embodiment, the electronic device is a motor winding bobbin5. The material of the terminal element4is gold, silver, copper, aluminum or any other conductive material.

The fixing portion41is used to connect with the connecting position51of the motor winding bobbin5. The fixing portion41is disposed on one end of the terminal element4and has a serrate fixing pattern41a. The serrate fixing pattern41acan increase the connecting strength between the fixing portion41and the connecting position51. In addition, the shape of the fixing portion41can be flat, conic, round or polygonal.

The serrate fixing pattern41acan be a regular or irregular pattern. The serrate fixing pattern41ais formed around the axial direction of the fixing portion41or at least one side of the fixing portion41.

The positioning portion42is disposed adjacent to the fixing portion41to urge against the motor winding bobbin5, thereby fixing the fixing portion41to the connecting position51of the motor winding bobbin5. The positioning portion42can be a protrusion or a plurality of bendings. In this embodiment, the positioning portion42is a protrusion.

The buffering portion43has a first bending431and a second bending432, and the first bending431is connected to the positioning portion42.

The terminal element4further has at least one connecting point44disposed at any position thereon other than the positioning portion42and the fixing portion41for electrically connecting with a motor winding.

The welding material6is disposed adjacent to the positioning portion42and the connecting position51of the motor winding bobbin5. In this embodiment, the welding material6covers the positioning portion42and the connecting position51of the motor winding bobbin5after welding.

With reference toFIG. 3, a manufacturing method for a motor winding structure according to a preferred embodiment of the invention includes the following steps S01to S03.

The step S01is inserting the fixing portion41of the terminal element4into the connecting position51of the motor winding bobbin5. As shown inFIG. 4A, when an external pulling force is imposed on the terminal element4, the fixing portion41is not easily pulled away from the connecting position51because of the stronger connecting force therebetween due to the serrate fixing pattern41a. Moreover, as the terminal element4is under this external pulling force, the buffering portion43absorbs most of the pulling force, so as to greatly reduce the strength of the external pulling force on the fixing portion41. In this embodiment, the positioning portion42has a third bending421and a fourth bending422, and the third bending421is connected to the fixing portion41. The bending direction of the third bending421of the positioning portion42is different from the extending direction of the fixing portion41.

The step S02is urging the positioning portion42of the terminal element4against the motor winding bobbin5. Please referringFIG. 4B, the positioning portion42prevents the terminal element4from further inserting into the connecting position51. Therefore, it can effectively avoid damages of the terminal element4on the connecting position51, and positions the terminal element4in the motor winding bobbin5precisely. As the terminal element4receives the inward pushing force, the positioning portion42and/or buffering portion43absorbs most of the force, so as to greatly reduce the strength of the pushing force on the terminal element4.

The step S03is covering the positioning portion42of the terminal element4and the connecting position51of the motor winding bobbin5by the welding material6. As shown inFIG. 4C, the welding material6increases the connecting force between the terminal element4and the motor winding bobbin5.

As mentioned above, the terminal element of the present invention has a serrate fixing pattern that can increase the connecting force between the terminal element and the electronic device so that the terminal element cannot be easily pulled away from the electronic device. Since the terminal element of the present invention has a positioning portion, the connecting depth of the terminal element in the connecting position of the electronic device can be accurately positioned. The buffering portion of the terminal element can greatly reduce the force applying on the contact portion between the terminal element and the connecting position of the electronic device. In addition, the terminal element and the motor winding bobbin are welded together by the welding material to increase the connecting force therebetween. The above-mentioned features of the present invention can prevent damages to the electronic device, increase the stability of the system, simplify the manufacturing process, and decrease the production cost.