Miniature air outlet motor assembly

Abstract

The utility model discloses a miniature air outlet motor assembly which comprises a motor structure, a transmission mechanism and a circuit structure. The system systematically solves the problems of large size, high noise, poor reliability and the like of a traditional air outlet motor through structural innovation, material optimization, process collaboration and system integration, has the technical effects of wide application prospects in the fields of automobile air conditioners, precise instruments and the like, and has remarkable market competitiveness and commercial potential.

Description

Technical Field

[0001] This utility model relates to a miniature air outlet motor assembly. Background Technology

[0002] Stepper motors are widely used in various automated control systems, and automotive air conditioning vents are equipped with drive motors. Currently, the motors used in automotive air conditioning vents have the following drawbacks:

[0003] 1. Insufficient transmission precision: Poor fixing precision between the gearbox and the drive shaft leads to increased wear and noise;

[0004] 2. Poor connection reliability: The motor is usually connected via an external power cord, which is an unreliable fixing method and is prone to loosening or poor contact;

[0005] 3. Noise issues: The noise level of a conventional stepper motor is >40dB during operation. Uneven gear meshing clearance exacerbates vibration and noise, affecting driving comfort. Utility Model Content

[0006] To address the aforementioned problems, this utility model provides a miniature air outlet motor assembly, which effectively solves the problems mentioned in the background art.

[0007] The technical solution adopted in this utility model is:

[0008] A miniature air outlet motor assembly includes a motor structure, a transmission mechanism, and a circuit structure;

[0009] Motor structure: includes a stator assembly and a rotor assembly. The stator assembly includes a housing, a wire frame and pole plates. The rotor assembly includes a central shaft and a magnetic ring structure fixed on the central shaft. The magnetic ring structure includes a magnetic ring frame fixed on the central shaft and magnetic rings respectively fixed at both ends of the magnetic ring frame.

[0010] Transmission mechanism: includes a worm and at least two cylindrical gears, the cylindrical gears are mounted in a plastic gearbox via a transmission shaft, the transmission shaft and the plastic gearbox are integrally formed by injection molding, the worm is fixed on a central shaft, and the worm and the cylindrical gears are meshed with each other;

[0011] Circuit structure: includes a flexible flat cable and a control board. One end of the flexible flat cable is electrically connected to the motor structure, and the other end is electrically connected to the control board. A power pin is fixed on the control board, and a power interface is provided at the power pin of the plastic gearbox.

[0012] Preferably, there are two pole plates, located on the outside of the two magnetic rings respectively, and the bases of the two pole plates are overlapped and fixed together. The pole plate teeth face the outer ends of the corresponding magnetic rings respectively. The wire frame includes two wire frame units respectively arranged on the outside of the pole plate teeth. The two wire frame units are fixedly connected together. The bases of the two pole plates are located between the two wire frame units. The wire frame unit is provided with a coil winding area, and a coil is wound in the coil winding area.

[0013] Preferably, the wire frame is made of plastic, the electrode plate is made of metal, the wire frame and the electrode plate are integrally formed, and the magnetic ring is made of high-performance neodymium iron boron permanent magnet material.

[0014] Preferably, the wire frame is provided with a wire outlet cover, which includes a housing connecting part and a wire frame support part fixed together. The wire frame support part has four pin holes. The housing connecting part extends laterally to the outside of the wire frame support part. The pins on the wire frame are inserted into the pin holes from the inside to the outside and extend out of the wire outlet cover. The motor structure is electrically connected to the flexible flat cable through the pins.

[0015] Preferably, a support platform is fixed to the outer side of the end of the drive shaft that is connected to the plastic gearbox body. The support platform is circular and fixed coaxially with the drive shaft.

[0016] Preferably, the flexible flat cable includes a flexible substrate layer and a conductive line layer disposed on the flexible substrate layer. At least two positioning holes A are provided on the flexible substrate layer, and the positioning holes A are distributed at the edge of the flexible substrate layer.

[0017] Preferably, the flexible substrate layer includes a first wiring area, a connection area, and a second wiring area. Each of the first wiring area, the connection area, and the second wiring area is provided with a positioning hole A, which is asymmetrically distributed on the flexible substrate layer.

[0018] Preferably, the motor structure is fixed to the plastic gearbox body by a shock-absorbing mechanism. The shock-absorbing mechanism includes fixed seats at both ends of the housing. The fixed seats are integrally formed with the plastic gearbox body. A rubber pad is provided between the fixed seat and the housing. The rubber pad prevents the housing from directly contacting the fixed seat. Multiple through holes are provided on the cover plates at both ends of the housing. At least two positioning posts that match the through holes are fixed on the side of the rubber pad facing the housing. The positioning posts are inserted into the through holes to prevent the housing from rotating radially.

[0019] Preferably, the rubber pad has a Shore A hardness of 65-75 degrees. The mounting base has a mounting groove on the side facing the housing, and the mounting groove matches the shape of the rubber pad. The rubber pad is inserted into the mounting groove. The top of the mounting groove is open. The outer side of the cover plate has an outwardly protruding positioning platform fixed at the axis of the housing. The center of the positioning platform has a shaft hole that matches the central axis. The rubber pad has a positioning hole B that matches the positioning platform. The positioning platform is inserted into the positioning hole B.

[0020] The innovative points of this utility model are:

[0021] 1. System integration design:

[0022] By highly integrating the motor structure, transmission mechanism, and circuit structure, a compact mechatronics structure is formed, solving the problems of large size and complex assembly in traditional motor systems. Specifically, this includes:

[0023] 11. Adopting a double-headed magnetic ring design (with a stepped magnetic field distribution), combined with the integrated molding process of the pole plate and wire frame, electromagnetic noise is reduced (<28dB), and the volume is reduced to 56×37×22mm (the traditional solution is 67×47×25mm), which improves the flexibility of the vehicle interior structure design.

[0024] 12. The drive shaft and the plastic gearbox body are integrally molded by injection molding. The parallelism error of the drive shaft is ≤0.02mm, the perpendicularity error is ≤0.05mm, the gear meshing clearance is uniform, and the transmission noise is ≤30dB.

[0025] 2. Collaborative optimization of noise reduction and vibration damping:

[0026] Vibration damping mechanism: The motor and the plastic gearbox are connected by rubber pads (Shore hardness 65-75 degrees), combined with the anti-rotation design of the positioning column and the through hole of the cover plate, which reduces vibration transmission by more than 30%.

[0027] Flexible flat cable and integrated interface: The drive signal line is replaced with a flexible flat cable (polyester imide substrate), and the power interface adopts automotive-grade connectors directly integrated into the plastic gearbox body to avoid poor contact caused by loose wiring harness;

[0028] 3. Material and process innovation:

[0029] High-performance neodymium iron boron magnetic rings: remanence 0.6-0.8T, coercivity 300-500kA / m, number of pole pairs 5-7, outer diameter 5.5-7.5mm, significantly improving electromagnetic efficiency and reducing vibration;

[0030] Engineering plastic gear assembly: The worm gear and cylindrical gear use POK, which has self-lubricating properties to reduce friction noise and reduce system weight;

[0031] High-temperature resistant synthetic rubber: The shock-absorbing rubber pads are oil-resistant and high-temperature resistant, adaptable to complex working conditions (such as automotive electrical appliances), and have a lifespan extended by more than 30%;

[0032] 4. Improved assembly and connection reliability:

[0033] Asymmetric positioning hole flexible flat cable: Asymmetric positioning holes (diameter Φ1-2mm, edge distance ≥0.5mm) are set at the edge of the flexible substrate layer to ensure unique welding alignment and reduce the defect rate by 50%;

[0034] The beneficial effects of this utility model are as follows:

[0035] 1. Significantly improved noise reduction performance:

[0036] Electromagnetic noise was reduced from >40dB to <28dB in the traditional solution, transmission noise was reduced from >35dB to ≤30dB, and overall noise was reduced by more than 40%.

[0037] Through multiple noise reduction designs such as double-headed magnetic ring stepped magnetic field distribution and rubber vibration isolation, the system's operational stability is improved, making it especially suitable for air conditioning systems in new energy vehicles with high requirements for quiet operation.

[0038] 2. Significantly reduced size and weight:

[0039] The motor's size has been reduced from 67×47×25mm to 56×37×22mm, a reduction of approximately 20% in volume and 15% in weight. The injection-molded one-piece plastic gearbox and integrated interface design reduce redundant components and improve space utilization by 30%.

[0040] 3. Enhanced connection reliability and lifespan:

[0041] Automotive-grade connectors are directly integrated into the plastic gearbox housing, improving connection reliability to 99.9% (reducing the loosening rate of traditional wiring harnesses by 80%).

[0042] The high-temperature resistant rubber pads and reinforced support ribs design ensure that the system remains stable during vibration testing (20-200Hz), extending its lifespan to over 100,000 hours.

[0043] 4. Optimization of assembly efficiency and maintenance costs:

[0044] Asymmetric positioning hole flexible cable reduces welding adjustment time, is compatible with ordinary welding equipment, and reduces production costs by 30%.

[0045] This system systematically solves the problems of large size, high noise, and poor reliability of traditional air outlet motors through structural innovation (integrated injection molding of double-headed magnetic ring, drive shaft and plastic gearbox), material optimization (neodymium iron boron magnetic ring, engineering plastics), process collaboration (flexible flat cable) and system integration (synergistic vibration isolation and noise reduction). Its technical effects have broad application prospects in the fields of automotive air conditioning and precision instruments, and have significant market competitiveness and commercial potential. Attached Figure Description

[0046] Figure 1 This is a schematic diagram of the structure of the present invention.

[0047] Figure 2 This is a schematic diagram of the internal structure of a plastic gearbox.

[0048] Figure 3 This is a schematic diagram of the exploded structure of the casing and rubber pad;

[0049] Figure 4 This is a structural diagram of the motor.

[0050] Figure 5 This is a schematic diagram of the cable outlet cover.

[0051] Figure 6 This is a schematic diagram of the cable outlet cover.

[0052] Figure 7 This is a cross-sectional structural diagram of the motor.

[0053] Figure 8 This is a schematic diagram of the internal structure of the motor.

[0054] Figure 9 This is a schematic diagram of the wire frame structure;

[0055] Figure 10 This is a schematic diagram of the pole plate and rotor assembly.

[0056] Figure 11 This is a schematic diagram of the magnetic ring structure;

[0057] Figure 12 This is a schematic diagram of the structure of a flexible flat cable. Detailed Implementation

[0058] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0059] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0060] Furthermore, in the description of this utility model, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0061] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, unless otherwise stated, "a plurality of" means two or more, unless otherwise expressly defined.

[0062] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0063] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0064] The present invention will now be described in further detail with reference to specific embodiments and accompanying drawings.

[0065] like Figure 1-12 As shown, a miniature air outlet motor assembly includes a motor structure, a transmission mechanism, and a circuit structure.

[0066] The motor structure includes a stator assembly and a rotor assembly. The stator assembly includes a housing 21, a wire frame 22, and pole plates 23. The rotor assembly includes a central shaft 24 and a magnetic ring structure 25 fixed on the central shaft 24. The magnetic ring structure 25 includes a magnetic ring frame 251 fixed on the central shaft 24 and magnetic rings 252 fixed at both ends of the magnetic ring frame 251. There are two pole plates 23, located outside the two magnetic rings 252 respectively, and the bases of the two pole plates 23 are overlapped and fixed together. The pole plate teeth 231 face the outer ends of the corresponding magnetic rings 252. The wire frame 22 includes two wire frame units 221 respectively disposed outside the pole plate teeth 231. 1. The two pole plates 23 are fixedly connected together, with their bases located between the two wire frame units 221. Each wire frame unit 221 has a coil winding area 222, in which a coil 223 is wound. The wire frame 22 is made of plastic, and the pole plates 23 are made of metal. The wire frame 22 and the pole plates 23 are integrally formed. The magnetic ring 252 uses high-performance neodymium iron boron permanent magnet material. The remanence of the high-performance neodymium iron boron permanent magnet material is 0.6~0.8T, the coercivity is 300~500kA / m, and the maximum energy product is 60~90kJ / m³. The magnetic ring 252 has 7 pole pairs, an outer diameter of 5.5~7.5mm, and a thickness of 0.8~1mm.The 8mm, 7-pair magnetic ring 252 allows for a smaller step angle, higher resolution, and less vibration in the motor, thus reducing electromagnetic noise. The wire frame 22 is equipped with a cable outlet cover 224, which includes a housing connecting part 2241 and a wire frame support part 2242 fixed together. The wire frame support part 2242 has four pin holes 2243. The housing connecting part 2241 extends laterally beyond the wire frame support part 2242. Pins on the wire frame 22 are inserted into the pin holes 2243 from the inside out and extend beyond the cable outlet cover 224. The motor structure is electrically connected to the flexible flat cable 41 via pins. The housing connecting part 2241 has an arc-shaped structure, and its outer surface matches the inner arc surface of the housing 21. The housing connecting part 2241 has... Two symmetrically fixed parts 2242 are attached to both sides of the wire frame support 2242. Two housing connecting parts 2241 are connected to the wire frame support 2242 via connecting plates 2244. The housing connecting parts 2241, connecting plates 2244, and wire frame support 2242 are integrally formed. The motor housing 21 has through holes at the location of the wire frame 22 that match the wire frame support 2242, allowing the wire frame support 2242 to pass through the through holes. The housing connecting parts 2241 are positioned inside the housing 21. When the cable outlet cover 224 is installed on the motor, the bottom of the wire frame support 2242 abuts against the wire frame 22, receiving an outward pushing force from the wire frame 22. The outer side of the housing connecting part 2241 abuts against the inner side of the housing 21, receiving an inward pushing force from the housing 21. This achieves stable fixing of the cable outlet cover 224.

[0067] Innovations in the motor structure:

[0068] 1. Double-headed magnetic ring design:

[0069] Traditional stepper motors use an integral magnetic ring, which results in a uniform magnetic field distribution and causes sudden changes in cogging torque, affecting low-speed stability. This invention uses a double-headed magnetic ring structure fixed at both ends of the magnetic ring frame, which makes the magnetic field distribution change in a stepped manner, significantly reducing cogging torque and improving running stability. The layout of the double magnetic rings optimizes the interaction of magnetic fields and reduces sudden changes in magnetic resistance, thereby reducing vibration and noise.

[0070] 2. Integrated design of electrode plate and wire frame:

[0071] The electrode bases are stacked and fixed, and the electrode teeth face the outer end of the corresponding magnetic ring. The wire frame units are set on the outside of the electrode teeth and fixedly connected to form a compact structure. The wire frame and electrode plates are made of plastic and metal in one piece, which simplifies the assembly process, enhances the structural stability, and reduces the additional noise caused by loose parts.

[0072] 3. High-performance neodymium iron boron magnetic ring material:

[0073] The magnetic ring uses neodymium iron boron material with optimized remanence (0.6~0.8T), coercivity (300~500kA / m) and maximum energy product (60~90kJ / m³) to improve magnetic field strength and efficiency. The refined design of the number of pole pairs (5~7 pairs) and outer diameter (5.5~7.5mm) of the magnetic ring further balances torque output and noise control.

[0074] 4. Protective structural design:

[0075] This utility model ensures uniform pin spacing by opening four pin holes on the wire frame support, avoiding the risk of short circuits caused by exposed wire ends touching each other in the traditional method. This design significantly improves the safety of stepper motor wiring.

[0076] 5. The arc-shaped structure of the housing connection:

[0077] The housing connection part adopts an arc design and matches the inner arc surface of the housing, so that the cable outlet cover can fit tightly into the housing, enhancing the stability and sealing of the connection. In addition, the two symmetrical housing connection parts are connected to the cable frame support part through the connecting plate, which further improves the stability of the overall structure and reduces the use of materials.

[0078] 6. One-piece molding technology:

[0079] The housing connection, connecting plate and wire frame support are made of one piece, which simplifies the manufacturing process, reduces assembly steps, lowers production costs, and improves the structural strength and durability of the product.

[0080] 7. Symmetrical design of the double-casing connection:

[0081] The two housing connection points are symmetrically distributed on both sides of the wire frame support, which not only optimizes the stress distribution, but also provides dual positioning and support for external connections, effectively preventing problems such as loose connections and broken enameled wires;

[0082] The transmission mechanism includes a worm gear 32 and at least two cylindrical gears 31. The cylindrical gears 31 are mounted inside a plastic gearbox 11 via a transmission shaft 33. The transmission shaft 33 and the plastic gearbox 11 are integrally formed by injection molding. The worm gear 32 is fixed to a central shaft 24. The worm gear 32 and the cylindrical gears 31 are meshed together. A support platform 34 is fixed to the outer side of the end of the transmission shaft 33 connected to the plastic gearbox 11. The support platform 34 is annular and coaxially fixed to the transmission shaft 33. The plastic gearbox 11 rests on the support platform 34. Multiple reinforcing ribs 35 are fixed on the outside. The plastic gearbox 11 has a support seat 36 coaxial with the support platform 34 fixed on the outside of the support platform 34. The support seat 36 is circular. The reinforcing ribs 35 are located between the support platform 34 and the support seat 36, and the two ends of the reinforcing ribs 35 are respectively connected to the support platform 34 and the support seat 36. The parallelism error between the shafts of the transmission shaft 33 is ≤0.02mm. The perpendicularity error between the transmission shaft 33 and the plastic gearbox 11 is ≤0.05mm. The worm gear 32 and the cylindrical gear 31 are both made of engineering plastic.

[0083] The innovative features of this utility model's transmission mechanism are:

[0084] 1. The drive shaft and the plastic gearbox body are injection molded as a single unit:

[0085] By using injection molding to form the drive shaft and plastic gearbox body in one piece, the traditional split assembly method is abandoned. This design eliminates the parallelism and perpendicularity deviations caused by assembly errors between the traditional drive shaft and the gearbox body, ensuring that the parallelism error between the drive shaft and the gearbox body is ≤0.02mm and the perpendicularity error with the gearbox body is ≤0.05mm, thereby directly controlling the uniformity of the gear meshing clearance.

[0086] 2. Composite structural design of support platform and reinforcing ribs:

[0087] A circular support platform is set at the connection end between the drive shaft and the housing, and radially distributed reinforcing ribs are added to its outer side. A circular support seat coaxial with the support platform is further set, and the two ends of the reinforcing ribs are fixed between the support platform and the support seat. This composite structure greatly improves the bending stiffness of the drive shaft and the overall stability of the housing, avoids shaft deformation caused by load vibration, and further ensures the long-term uniformity of the meshing clearance.

[0088] 3. Optimized application of engineering plastic gear assemblies:

[0089] Both the worm gear and the cylindrical gear are made of high-strength engineering plastics (such as POK). Compared with metal gears, engineering plastics have self-lubricating properties, which significantly reduces frictional noise during gear meshing.

[0090] Circuit structure: Includes a flexible flat cable 41 and a control board 42. One end of the flexible flat cable 41 is electrically connected to the motor structure, and the other end is electrically connected to the control board 42. A power pin 43 is fixed on the control board 42. The plastic gearbox 1 has a power interface 111 at the power pin 43. The power interface 111 uses automotive-grade connectors and is directly integrated into the plastic gearbox 11 to prevent the wiring harness from loosening. The flexible flat cable 41 includes a flexible substrate layer 411 and a conductive line layer disposed on the flexible substrate layer 411. Since it is a conventional technique to place the conductive line layer on the flexible substrate layer 411, the conductive line layer is not identified in the drawings. The flexible substrate layer 411 has at least Two positioning holes A412 are distributed at the edge of the flexible substrate layer 411. The flexible substrate layer 411 includes a first wiring area 4111, a connecting area 4112, and a second wiring area 4113. Positioning holes A412 are provided on the first wiring area 4111, the connecting area 4112, and the second wiring area 4113. The positioning holes A412 are asymmetrically distributed on the flexible substrate layer 411. The distance between the positioning hole A412 and the edge of the flexible substrate layer 411 is greater than or equal to 0.5 mm. The aperture range of the positioning hole A412 is [1, 2] mm. The flexible substrate layer 411 is made of polyesterimide or polyester. The conductive circuit layer is disposed on the surface of the flexible substrate layer 411.

[0091] The motor structure is fixed inside the plastic gearbox 11 by a shock-absorbing mechanism. The shock-absorbing mechanism includes a fixing seat 51 at both ends of the housing 21. The fixing seat 51 is integrally formed with the plastic gearbox 11. A rubber pad 52 is provided between the fixing seat 51 and the housing 21. The rubber pad 52 prevents the housing 21 from directly contacting the fixing seat 51. Multiple through holes 54 are provided on the cover plates 53 at both ends of the housing 21. At least two positioning posts 55 that match the through holes 54 are fixed on the side of the rubber pad 52 facing the housing 21. The positioning posts 55 are inserted into the through holes 54 to prevent the housing 21 from rotating radially.

[0092] The rubber pad 52 has a Shore A hardness of 65-75 degrees. The mounting base 51 has a mounting groove 56 on the side facing the housing 21. The mounting groove 56 matches the shape of the rubber pad 52. The rubber pad 52 is inserted into the mounting groove 56. The top of the mounting groove 56 is open. The outer side of the cover plate 53 has an outwardly protruding positioning platform 57 fixed at the axis of the housing 21. The center of the positioning platform 57 has a shaft hole 58 that matches the central shaft 24. The rubber pad 52 has a positioning hole B59 that matches the positioning platform 57. The positioning platform 57 is inserted into the positioning hole B59.

[0093] The mounting base 51 has a U-shaped hole 510 that passes through the mounting base 51 axially in the motor structure. The top of the U-shaped hole 510 is open. The mounting base 51 has multiple reinforcing support ribs 511 fixed on the side away from the motor structure. The rubber pad 52 is made of oil-resistant and high-temperature resistant synthetic rubber.

[0094] The innovative features of this shock absorption mechanism are:

[0095] 1. Matching design between the rubber pad and the mounting slot of the fixing seat:

[0096] The mounting base has a mounting groove on the side facing the motor that matches the shape of the rubber pad. The rubber pad is precisely positioned by snapping into the mounting groove. The top of the mounting groove is open for easy assembly and disassembly.

[0097] Technical benefits: Simplifies installation steps and improves assembly accuracy; reduces displacement of rubber pads during operation through tight fit, enhancing shock absorption stability;

[0098] 2. Anti-rotation structure for the positioning post and the through hole of the cover plate:

[0099] At least two positioning posts are fixed on the side of the rubber pad facing the motor, which match and engage with the through holes on the motor cover plate. The positioning posts are 1.3mm in diameter and 1mm in height.

[0100] Technical effects: Effectively limits the radial rotation of the motor, preventing displacement deviation caused by vibration; improves the connection rigidity between the motor and the fixed structure, while retaining the elastic deformation space required for shock absorption;

[0101] 3. Strengthen the supporting ribs to improve the strength of the fixing seat:

[0102] The mounting base has multiple reinforcing ribs on the side away from the motor to optimize the mechanical distribution;

[0103] Technical effects: Significantly enhances the bending and torsional resistance of the mounting base, preventing fatigue deformation caused by long-term vibration; extends the service life of the mounting structure;

[0104] 4. Oil-resistant and high-temperature resistant synthetic rubber material:

[0105] The rubber pads are made of oil-resistant and high-temperature-resistant synthetic rubber (Shore A hardness 65-75 degrees), combining elasticity and durability;

[0106] Technical benefits: It adapts to harsh working conditions such as high temperature and oil pollution, and avoids rubber aging and cracking; while ensuring shock absorption performance, it provides stable support and extends the overall life of the device.

[0107] The innovative aspects of the circuit structure of this utility model are:

[0108] 1. Asymmetrical positioning hole design:

[0109] At least two circular positioning holes are set in a 1-2mm area at the edge of the flexible substrate layer. The asymmetrical distribution effectively avoids misalignment or reverse installation during assembly. The asymmetrical layout combined with physical positioning characteristics significantly improves the uniqueness and reliability of the assembly.

[0110] 2. Precise matching of the bore diameter and the locating pin:

[0111] The positioning hole diameter ranges from Φ1 to Φ2mm, and the hole diameter is 0.1 to 0.2mm larger than the diameter of the positioning pin of the welding equipment. This ensures smooth insertion of the positioning pin and avoids misalignment due to excessive gap. Through size optimization, while meeting assembly accuracy, it prevents the FPC flexible flat cable from interfering with other components due to excessive hole diameter.

[0112] 3. Optimized edge tear resistance structure:

[0113] The minimum distance from the edge of the positioning hole to the edge of the FPC flexible cable is ≥0.5mm, which enhances the mechanical strength of the area around the hole and avoids material tearing caused by stress concentration during processing or assembly.

[0114] 4. Co-design of flexible substrate layer and conductive circuit layer:

[0115] The flexible substrate layer is made of polyesterimide (PI) or polyester (PET) material, which combines flexibility, high temperature resistance and dimensional stability, ensuring that the FPC is not easily deformed during the welding process. The conductive line layer is precisely formed by etching process and designed in coordination with the positioning hole position to avoid the line overlapping with the positioning hole area and ensure electrical performance.

[0116] This invention achieves low-noise, high-precision airflow control through electromechanical co-design. The core working principle is as follows:

[0117] 1. Electromagnetic drive and silent control:

[0118] Core component: Motor structure (dual-head magnetic ring design):

[0119] Magnetic field generation: After energization, the coils on the wire frame generate an alternating magnetic field. The magnetic field of the double-headed magnetic ring (fixed at both ends of the rotor magnetic ring frame) is distributed in a stepped manner, which is different from the uniform magnetic field of the traditional integral magnetic ring. It can smooth the change of magnetic resistance and reduce the sudden change of cogging torque.

[0120] Rotor motion: The interaction of magnetic fields drives the rotor to rotate. The stepped magnetic field of the double magnetic ring reduces magnetic resistance fluctuation by more than 60%, significantly reducing vibration and electromagnetic noise (<28dB).

[0121] Material optimization: The magnetic ring uses high-performance neodymium iron boron material (remanence 0.6-0.8T, coercivity 300-500kA / m), which can still output stable torque and reduce energy loss under miniaturized design.

[0122] 2. Low-noise gear transmission:

[0123] Core components: Transmission mechanism, the transmission shaft and plastic gearbox are integrally injection molded, and the worm gear and cylindrical gear are made of engineering plastics;

[0124] Integrated drive shaft molding: The drive shaft and the plastic gearbox body are integrally molded through injection molding, eliminating the parallelism error (error ≤ 0.02mm) of traditional separate assembly and ensuring uniform gear meshing clearance;

[0125] Worm Gear Reduction and Noise Reduction: The worm and cylindrical gear are made of engineering plastic (POK), which utilizes the material's self-lubricating properties to reduce friction noise; the worm gear reduction structure reduces the transmission volume and lowers speed fluctuations.

[0126] Strengthened support design: The end of the drive shaft is equipped with a circular support platform, with reinforcing ribs and support seats distributed on the outside to improve bending stiffness and suppress gear misalignment caused by load vibration.

[0127] 3. Seismic isolation and damping mechanisms:

[0128] Core component: shock absorption mechanism;

[0129] Vibration isolation material absorbs vibration: The housing and the plastic gearbox are connected by a silicone rubber pad with a Shore hardness of 65-75, which converts high-frequency vibration into heat energy and reduces the vibration amplitude transmitted to the plastic gearbox (reduction > 30%).

[0130] Positioning pins prevent displacement: Positioning pins are set on the rubber pads and engage with the through holes of the motor cover plate to limit the radial rotation of the motor, while retaining elastic deformation space to balance shock absorption and stability;

[0131] Noise reduction with flexible flat cable: The drive signal line uses polyesterimide flexible flat cable to reduce the transmission of mechanical vibration and avoid additional noise caused by wire harness friction.

[0132] 4. Reliable connection:

[0133] Core component: Automotive-grade integrated interface;

[0134] Integrated power interface: Automotive-grade connectors are directly integrated into the plastic gearbox housing, replacing traditional wiring harness connectors. Contact resistance is reduced to <0.1Ω, avoiding signal interruption caused by loosening.

[0135] 5. Flexible circuits and precision soldering:

[0136] Core component: Asymmetric positioning hole flexible flat cable;

[0137] Physical positioning to prevent errors: Asymmetrical positioning holes (1-2mm in diameter) are provided at the edge of the flexible substrate layer to match the positioning pins of the welding equipment, ensuring a unique assembly direction and reducing the rate of false welds by 50%;

[0138] Stable high-temperature resistant materials: The polyesterimide substrate has a temperature resistance of >200℃, maintains shape stability during welding, and the conductive lines avoid the positioning hole area to avoid the risk of short circuit.

[0139] Finally, it should be noted that the above examples are merely specific embodiments of this utility model. Obviously, this utility model is not limited to the above embodiments and can have many variations. All variations that can be directly derived or conceived by those skilled in the art from the disclosure of this utility model should be considered within the protection scope of this utility model.

Claims

1. A miniature air outlet motor assembly, characterized in that, The system includes a motor structure, a transmission mechanism, and a circuit structure. The motor structure includes a stator assembly and a rotor assembly. The stator assembly includes a housing (21), a wire frame (22), and pole plates (23). The rotor assembly includes a central shaft (24) and a magnetic ring structure (25) fixed to the central shaft (24). The magnetic ring structure (25) includes a magnetic ring frame (251) fixed to the central shaft (24) and magnetic rings (252) fixed to both ends of the magnetic ring frame (251). The transmission mechanism includes a worm gear (32) and at least two cylindrical gears (31). The cylindrical gears (31) are connected via a transmission shaft (…). 33) Installed inside the plastic gearbox (1), the drive shaft (33) and the plastic gearbox (1) are integrally formed by injection molding process, the worm (32) is fixed on the central shaft (24), and the worm (32) and the cylindrical gear (31) are meshed with each other; Circuit structure: including a flexible flat cable (41) and a control board (42), one end of the flexible flat cable (41) is electrically connected to the motor structure, and the other end is electrically connected to the control board (42), the control board (42) is fixed with a power pin (43), and the plastic gearbox (1) is provided with a power interface (111) at the power pin (43).

2. The miniature air outlet motor assembly according to claim 1, characterized in that, There are two pole plates (23), which are located on the outside of the two magnetic rings (252) respectively, and the bases of the two pole plates (23) are overlapped and fixed together. The pole plate teeth (231) face the outer end of the corresponding magnetic ring (252) respectively. The wire frame (22) includes two wire frame units (221) respectively set on the outside of the pole plate teeth (231). The two wire frame units (221) are fixedly connected together. The bases of the two pole plates (23) are located between the two wire frame units (221). The wire frame unit (221) is provided with a coil winding area (222), and a coil (223) is wound in the coil winding area (222).

3. The miniature air outlet motor assembly according to claim 2, characterized in that, The wire frame (22) is made of plastic, the electrode plate (23) is made of metal, the wire frame (22) and the electrode plate (23) are integrally formed, and the magnetic ring (252) is made of high-performance neodymium iron boron permanent magnet material.

4. The miniature air outlet motor assembly according to claim 1, characterized in that, The wire frame (22) is provided with a wire outlet cover (224). The wire outlet cover (224) includes a housing connecting part (2241) and a wire frame support part (2242) fixed together. The wire frame support part (2242) is provided with four pin holes (2243). The housing connecting part (2241) extends laterally to the outside of the wire frame support part (2242). The pins on the wire frame (22) are inserted into the pin holes (2243) from the inside to the outside and extend out of the wire outlet cover (224). The motor structure is electrically connected to the flexible flat cable (41) through the pins.

5. A miniature air outlet motor assembly according to claim 1, characterized in that, The drive shaft (33) has a support platform (34) fixed on the outer side of the end connected to the plastic gearbox (1). The support platform (34) is circular and is fixed coaxially with the drive shaft (33).

6. The miniature air outlet motor assembly according to claim 1, characterized in that, The flexible flat cable (41) includes a flexible substrate layer (411) and a conductive line layer disposed on the flexible substrate layer (411). At least two positioning holes A (412) are provided on the flexible substrate layer (411), and the positioning holes A (412) are distributed at the edge of the flexible substrate layer (411).

7. A miniature air outlet motor assembly according to claim 6, characterized in that, The flexible substrate layer (411) includes a first wiring area (4111), a connection area (4112), and a second wiring area (4113). The first wiring area (4111), the connection area (4112), and the second wiring area (4113) are all provided with positioning holes A (412). The positioning holes A (412) are asymmetrically distributed on the flexible substrate layer (411).

8. A miniature air outlet motor assembly according to claim 1, characterized in that, The motor structure is fixed inside the plastic gearbox (1) by a shock-absorbing mechanism. The shock-absorbing mechanism includes a fixed seat (51) at both ends of the housing (21). The fixed seat (51) is integrally formed with the plastic gearbox (1). A rubber pad (52) is provided between the fixed seat (51) and the housing (21). The rubber pad (52) isolates the housing (21) from direct contact with the fixed seat (51). Multiple through holes (54) are provided on the cover plates (53) at both ends of the housing (21). At least two positioning pins (55) matching the through holes (54) are fixed on the side of the rubber pad (52) facing the housing (21). The positioning pins (55) are inserted into the through holes (54) to prevent the housing (21) from rotating radially.

9. A miniature air outlet motor assembly according to claim 8, characterized in that, The rubber pad (52) has a Shore A hardness of 65-75 degrees. The mounting base (51) has an installation groove (56) on the side facing the housing (21). The installation groove (56) matches the shape of the rubber pad (52). The rubber pad (52) is inserted into the installation groove (56). The top of the installation groove (56) is designed to be open. The outer side of the cover plate (53) has an outwardly protruding positioning platform (57) fixed at the axis of the housing (21). The center of the positioning platform (57) has a shaft hole (58) that matches the central shaft (24). The rubber pad (52) has a positioning hole B (59) that matches the positioning platform (57). The positioning platform (57) is inserted into the positioning hole B (59).

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