A brushless blower motor terminal-free wiring connection structure

Abstract

The application discloses a terminal-free wiring connection structure of a brushless blowing motor, and relates to the technical field of blowing motors, comprising a sealing insulation piece, wherein the sealing insulation piece is used for allowing a stator wire to pass through and be electrically connected with a PCB assembly; the sealing insulation piece is composed of a soft rubber connecting part and a hard rubber connecting part which is inserted into the soft rubber connecting part, and a stator pipeline penetrates through the soft rubber connecting part and the hard rubber connecting part and is wrapped with sealing silica gel. The soft rubber connecting part and the hard rubber connecting part are combined to form a sealing structure to cooperate with the sealing silica gel, and the wiring terminal and the crimping process are cancelled, so that the sealing protection performance is improved, the structural combination strength is enhanced, and the wiring stability is improved.

Description

Technical Field

[0001] This application relates to the field of blower motor technology, and in particular to a terminal-free wiring connection structure for a brushless blower motor. Background Technology

[0002] Currently, the stator windings of brushless blower motors used in automotive air conditioning systems commonly employ a terminal-connection wiring structure between the stator windings and the PCB driver board. This structure requires first crimping and fixing the stator winding leads to metal terminals, then passing the wires with the assembled terminals through a seal, and finally soldering the terminals to the pads on the PCB driver board for electrical connection. The entire electrical connection relies on metal terminals for intermediate connection, which is a conventional technical solution that has been used in the industry for a long time.

[0003] However, the adapter-type wiring structure involves complex processing steps in actual production. In use, it requires dedicated terminals and an additional crimping process, resulting in low assembly efficiency and a high risk of rework due to improper crimping or terminal deformation. Furthermore, the procurement and inventory management of terminal materials increase overall production costs. The intermediate adapter links introduce multiple electrical contact points. Over long-term operation, the connections between wires and terminals, and between terminals and the PCB, are prone to oxidation and loosening, leading to increased contact resistance, poor contact, or even open circuits, directly impacting the electrical reliability of the motor.

[0004] Regarding sealing and protection, due to the assembly gaps between the terminals and seals, and between the winding wires and terminals, it is difficult to achieve high-level IP protection. Furthermore, under the complex operating conditions of automotive air conditioning systems, which are humid and dusty, moisture and impurities can easily penetrate into the motor, leading to insulation degradation, short circuits, and other faults. This cannot meet the sealing and protection requirements for the long-term stable operation of automotive motors and needs to be improved. Summary of the Invention

[0005] In view of this, the purpose of this application is to provide a terminal-free wiring connection structure for a brushless blower motor, so as to improve electrical reliability, sealing and protection performance. The specific solution is as follows: A terminal-free wiring connection structure for a brushless blower motor includes a sealing and insulating component through which stator wires pass and are electrically connected to a PCB assembly. The sealing and insulating component consists of a soft rubber connector and a hard rubber connector inserted into the soft rubber connector. The stator wires pass through the soft rubber connector and the hard rubber connector and are wrapped with sealing silicone.

[0006] Preferably, a fixing seat is provided between the stator conductor and the PCB assembly. The PCB assembly is fixed to one side of the fixing seat by screws or adhesive. A stator fixing seat is provided on the other side of the fixing seat. The stator fixing seat is connected to the stator by a snap-fit ​​and is provided with multiple lead-in holes for matching the sealing insulation component and for the stator conductor to pass through. The fixing seat is an aluminum base.

[0007] Preferably, at least one of the lead-in sockets is convex.

[0008] Preferably, the soft rubber connecting part includes a soft rubber mating groove, a soft rubber through hole, and a plurality of soft rubber insertion parts; the hard rubber support part is provided with a hard rubber mating groove that is inserted into the soft rubber mating groove and a hard rubber through hole that matches the soft rubber through hole.

[0009] Preferably, the outer side of the soft rubber connector is provided with a soft rubber mating groove, and a soft rubber embedded groove is formed on the soft rubber mating groove; the hard rubber support is provided with a hard rubber mating part that matches the soft rubber mating groove and the hard rubber mating part is flush with the outer side of the soft rubber connector, and a hard rubber embedded groove that matches the soft rubber embedded groove is provided.

[0010] Preferably, at least one of the soft rubber plugs is convex.

[0011] Preferably, the soft rubber connecting part and the hard rubber supporting part are integrally formed.

[0012] Preferably, the soft rubber connector is obtained by injection molding of TPE, and the hard rubber connector is obtained by injection molding of PBT and GF30.

[0013] Preferably, the soft adhesive connector comprises 55-70 parts by weight of maleic anhydride-grafted SEBS, 10-20 parts by weight of polypropylene, 1-3 parts by weight of organosilane coupling agent, 5-12 parts by weight of tackifying resin, 3-8 parts by weight of softening oil, and 0.3-0.8 parts by weight of antioxidant.

[0014] Preferably, the rigid adhesive connector comprises 55-70 parts by weight of PBT resin, 30-35 parts by weight of glass fiber, 0.5-2 parts by weight of epoxy silane coupling agent, 1-3 parts by weight of carboxyl-modified compatibilizer, 0.5-1.5 parts by weight of nano-silica, and 0.3-0.8 parts by weight of antioxidant.

[0015] As can be seen from the above solutions, this application provides a terminal-free wiring connection structure for a brushless blower motor, which has the following beneficial effects: 1. A sealing structure is formed by combining soft and hard rubber connectors to cooperate with the sealing silicone coating, eliminating the need for terminals and crimping processes. This improves sealing and protection performance, strengthens structural bonding, and enhances wiring stability. 2. The soft adhesive joint is composed of maleic anhydride grafted SEBS, polypropylene, organosilane coupling agent, tackifying resin, softening oil and antioxidant. The organosilane coupling agent forms a chemical bond at the interface between the soft adhesive joint and the hard adhesive joint. The tackifying resin improves the interface wettability and adhesion. The softening oil ensures the flexibility of the material. 3. The rigid adhesive joint uses PBT resin and glass fiber as the matrix, and works synergistically with epoxy silane coupling agent, carboxyl modified compatibilizer, nano silica and antioxidant. The epoxy silane coupling agent enhances the interfacial bonding force between glass fiber and PBT resin, the carboxyl modified compatibilizer improves the interfacial compatibility between the two phases, and the nano silica improves hardness and dimensional stability. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this application. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the terminal-free wiring connection structure of the brushless blower motor disclosed in this application; Figure 2 This is an exploded structural diagram of the terminal-free wiring connection structure of the brushless blower motor disclosed in this application; Figure 3 for Figure 2 A magnified structural diagram of part A in the middle; Figure 4 This is a schematic diagram of the sealed insulating component of the terminal-free wiring connection structure of the brushless blower motor disclosed in this application.

[0018] Explanation of reference numerals in the attached drawings: 1. Stator; 2. Mounting base; 21. Stator mounting base; 211. Lead wire insertion hole; 3. PCB assembly; 4. Sealing and insulating component; 41. Soft rubber connection part; 411. Soft rubber mating groove; 412. Soft rubber through hole; 413. Soft rubber mating groove; 414. Soft rubber embedded groove; 415. Soft rubber insertion part; 42. Hard rubber support part; 421. Hard rubber mating body; 422. Hard rubber through hole; 423. Hard rubber mating part; 424. Hard rubber embedded groove. Detailed Implementation

[0019] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0020] It should be mentioned that the organosilane coupling agent in this application embodiment is KH-570, the softening oil is KN4010 naphthenic oil, the soft adhesive antioxidant is Irganox-B225 antioxidant, the epoxy silane coupling agent is KH-560, the carboxyl-modified compatibilizer is DuPont P353 compatibilizer, and the hard adhesive antioxidant is Irganox1010 antioxidant. All of these are commercially available and will not be described in detail here. The fixing base is an aluminum base, die-cast by a die-casting machine according to a mold; this will also not be described in detail here.

[0021] Example 1 like Figure 1 As shown, a terminal-free wiring connection structure for a brushless blower motor includes a sealed insulating component 4. The sealed insulating component 4 allows stator 1 conductors to pass through and connect electrically to the PCB assembly 3. The sealed insulating component 4 consists of a soft rubber connecting part 41 and a hard rubber connecting part inserted into the soft rubber connecting part 41, such as... Figure 4 As shown, the stator 1 pipeline passes through the soft rubber connection part 41 and the hard rubber connection part and is wrapped with sealing silicone.

[0022] It should be noted that, as Figure 2 , Figure 3 As shown, a mounting bracket 2 is provided between the stator 1 conductor and the PCB assembly 3. The PCB assembly 3 is fixed to one side of the mounting bracket 2 by screws or adhesive. In this embodiment, bolts are used to fix the PCB assembly 3 and the mounting bracket 2.

[0023] A stator 1 fixing seat 2 is provided on the other side of the fixing seat 2. The stator 1 fixing seat 2 is snap-fitted to the stator 1 and is provided with a plurality of lead-in holes 211 for matching with the sealing insulation component 4 and for the stator 1 wires to pass through. In order to improve the fixing stability of the sealing insulation component 4, at least one lead-in hole 211 is convex.

[0024] like Figure 4As shown, the soft rubber connecting part 41 is provided with a soft rubber mating groove 413411, a soft rubber through hole 412, and a plurality of soft rubber insertion parts 415, at least one of which is convex. The hard rubber connecting part is provided with a hard rubber mating groove that can be inserted into the soft rubber mating groove 413411, and a hard rubber through hole 422 that matches the soft rubber through hole 412. The soft rubber connecting part 41 is provided with a soft rubber mating groove 413411 on its outer side, and a soft rubber embedded groove 414 is formed on the soft rubber mating groove 413411; the hard rubber connecting part is provided with a hard rubber mating part 423 that matches the soft rubber mating groove 413411, the hard rubber mating part 423 is flush with the outer side of the soft rubber connecting part 41, and is provided with a hard rubber embedded groove 424 that matches the soft rubber embedded groove 414.

[0025] The soft rubber connector 41 and the hard rubber connector are integrally molded. The soft rubber connector 41 is injection molded from modified TPE material, which, by weight, includes: 65 parts maleic anhydride-grafted SEBS, 15 parts polypropylene, 2 parts organosilane coupling agent, 8 parts tackifying resin, 5 parts softening oil, and 0.5 parts antioxidant.

[0026] The rigid adhesive connector is injection molded from modified PBT with GF30 material, which by weight includes: 65 parts PBT resin, 32 parts glass fiber, 1 part epoxy silane coupling agent, 2 parts carboxyl modified compatibilizer, 1 part nano silica and 0.5 parts antioxidant.

[0027] Example 2 The difference between Example 2 and Example 1 is that the soft rubber connecting part 41 in Example 2 is injection molded from modified TPE material, which includes, by weight: 55 parts maleic anhydride grafted SEBS, 10 parts polypropylene, 1 part organosilane coupling agent, 5 parts tackifying resin, 3 parts softening oil and 0.3 parts antioxidant.

[0028] The rigid adhesive connector is injection molded from modified PBT with GF30 material, which by weight includes: 55 parts PBT resin, 30 parts glass fiber, 0.5 parts epoxy silane coupling agent, 1 part carboxyl modified compatibilizer, 0.5 parts nano silica and 0.3 parts antioxidant.

[0029] Example 3 The difference between Example 3 and Example 1 is that the soft rubber connecting part 41 in Example 3 is injection molded from modified TPE material, which includes, by weight: 70 parts maleic anhydride grafted SEBS, 20 parts polypropylene, 3 parts organosilane coupling agent, 12 parts tackifying resin, 8 parts softening oil and 0.8 parts antioxidant.

[0030] The rigid adhesive connector is injection molded from modified PBT with GF30 material, which by weight includes: 70 parts PBT resin, 35 parts glass fiber, 2 parts epoxy silane coupling agent, 3 parts carboxyl modified compatibilizer, 1.5 parts nano silica and 0.8 parts antioxidant.

[0031] Example 4 The difference between Example 4 and Example 1 is that the soft rubber connector 41 in Example 4 is obtained by TPE injection molding.

[0032] Performance testing: 1. Protection rating: Based on GB / T 4208-2017 "Degrees of protection provided by enclosures (IP codes)," an IP6K5 / IPX7 waterproof and dustproof test was conducted to obtain a sealing effect; 2. Interfacial peel strength: According to GB / T 2790-1995 "Adhesives - 180° Peel Strength Test Method - Flexible Materials vs. Rigid Materials", a sealed insulating part was used as the sample with a width of 25 mm, a peel speed of 300 mm / min, a test temperature of (23±2)℃, and a humidity of (50±5)% RH to obtain the interfacial peel strength between the soft adhesive joint and the hard adhesive joint. 3. Shear strength: According to GB / T 7124-2008 "Determination of tensile shear strength of adhesives (rigid material to rigid material)", the sealing insulation component is taken as the specimen, and the single lap specimen is used. The tensile speed is 10 mm / min. The shear strength of the bond between the sealing silicone and the sealing insulation component is calculated. The performance test results are shown in Table 1 below.

[0033] Table 1 Performance Test Results

[0034] As shown in Table 1 above, this application achieves enhanced chemical bonding between the soft rubber connector 41 and the hard rubber connector by using maleic anhydride-grafted SEBS, organosilane coupling agent, and tackifying resin in the soft rubber connector 41. The tackifying resin improves the interface wettability and adhesion, and the softening oil ensures the toughness of the material, so that the soft rubber connector 41 and the hard rubber connector form a stable bond. This maintains the connection structure during long-term vibration and high and low temperature cycling, significantly improving the sealing reliability.

[0035] In summary, this application provides a terminal-free wiring connection structure for a brushless blower motor. This terminal-free wiring connection structure forms a sealed structure through a combination of a soft adhesive connection part 41 and a hard adhesive connection part to cooperate with the sealing silicone coating, eliminating the need for terminals and crimping processes. This structure improves sealing and protection performance, enhances structural bonding strength, and improves wiring stability. Specifically, the soft adhesive connection part 41 is composed of maleic anhydride-grafted SEBS, polypropylene, organosilane coupling agent, tackifying resin, softening oil, and antioxidant. The organosilane coupling agent forms chemical bonds at the interface between the soft adhesive connection part 41 and the hard adhesive connection part, the tackifying resin improves interface wettability and adhesion, and the softening oil ensures material flexibility. The rigid adhesive joint uses PBT resin and glass fiber as the matrix, and works synergistically with epoxy silane coupling agent, carboxyl modified compatibilizer, nano silica and antioxidant. The epoxy silane coupling agent enhances the interfacial bonding force between glass fiber and PBT resin, the carboxyl modified compatibilizer improves the interfacial compatibility between the two phases, and the nano silica improves hardness and dimensional stability.

[0036] The terms “first,” “second,” “third,” “fourth,” etc., used in this application (if applicable) are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms “comprising” and “having,” and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, or apparatus that includes a series of steps or units is not necessarily limited to those explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, or apparatus.

[0037] It should be noted that the use of terms such as "first" and "second" in this application is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of those features. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If the combination of technical solutions is contradictory or impossible to implement, such a combination of technical solutions should be considered non-existent and not within the scope of protection claimed in this application.

[0038] This document uses specific examples to illustrate the principles and implementation methods of this application. The descriptions of the above embodiments are only for the purpose of helping to understand the methods and core ideas of this application. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of this application. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A terminal-free wiring connection structure for a brushless blower motor, characterized in that: The device includes a sealing insulation component through which stator conductors pass and are electrically connected to the PCB assembly. The sealing insulation component consists of a soft rubber connector and a hard rubber connector inserted into the soft rubber connector, and the stator conductors pass through the soft rubber connector and the hard rubber connector and are wrapped with sealing silicone.

2. The terminal-free wiring connection structure for a brushless blower motor according to claim 1, characterized in that: A mounting bracket is provided between the stator conductor and the PCB assembly. The PCB assembly is fixed to one side of the mounting bracket by screws or adhesive. A stator mounting bracket is provided on the other side of the mounting bracket. The stator mounting bracket is connected to the stator by a snap-fit ​​and is provided with multiple lead-in holes for matching the sealing insulation component and for the stator conductor to pass through. The mounting bracket is an aluminum bracket.

3. The terminal-free wiring connection structure for a brushless blower motor according to claim 2, characterized in that: At least one of the lead sockets is convex.

4. The terminal-free wiring connection structure for a brushless blower motor according to claim 1, characterized in that: The soft rubber connector includes a soft rubber mating groove, a soft rubber through hole, and multiple soft rubber insertion parts; the hard rubber support part is provided with a hard rubber mating groove that inserts into the soft rubber mating groove and a hard rubber through hole that matches the soft rubber through hole.

5. The terminal-free wiring connection structure for a brushless blower motor according to claim 4, characterized in that: The outer side of the soft rubber connector is provided with a soft rubber mating groove, and a soft rubber embedded groove is formed on the soft rubber mating groove; the hard rubber support is provided with a hard rubber mating part that matches the soft rubber mating groove and the hard rubber mating part is flush with the outer side of the soft rubber connector, and a hard rubber embedded groove that matches the soft rubber embedded groove is provided.

6. The terminal-free wiring connection structure for a brushless blower motor according to claim 4, characterized in that: At least one of the soft rubber connectors is convex.

7. The terminal-free wiring connection structure for a brushless blower motor according to claim 1, characterized in that: The soft rubber connecting part and the hard rubber supporting part are integrally formed.

8. The terminal-free wiring connection structure for a brushless blower motor according to claim 1, characterized in that: The soft rubber connector is obtained by injection molding of TPE, and the hard rubber connector is obtained by injection molding of PBT and GF30.

9. The terminal-free wiring connection structure for a brushless blower motor according to claim 8, characterized in that: The soft adhesive connector comprises 55-70 parts by weight of maleic anhydride-grafted SEBS, 10-20 parts of polypropylene, 1-3 parts of organosilane coupling agent, 5-12 parts of tackifying resin, 3-8 parts of softening oil, and 0.3-0.8 parts of soft adhesive antioxidant.

10. The terminal-free wiring connection structure for a brushless blower motor according to claim 8, characterized in that: The rigid adhesive connector comprises 55-70 parts by weight of PBT resin, 30-35 parts by weight of glass fiber, 0.5-2 parts by weight of epoxy silane coupling agent, 1-3 parts by weight of carboxyl-modified compatibilizer, 0.5-1.5 parts by weight of nano-silica, and 0.3-0.8 parts by weight of rigid adhesive antioxidant.

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