BLOWER MOTOR DEVICE

Abstract

A blower motor device (1) for a vehicle's heating, ventilation, and air conditioning system comprises an electronics housing (12) containing electronic components (8) mounted on a printed circuit board (PCB) 9, a stator (5) comprising a stack of axially (4) stacked steel sheets (7), and a plurality of circumferentially (17) spaced-apart winding coils (6), wherein the stator (5) is connected to the electronics housing (12) and is rotationally fixed with respect to the electronics housing (12). According to the invention, the electronics housing (12) comprises a plastic material that is overmolded around the PCB (9) and the electronic components (8).

Description

[0001] The invention relates to a blower motor device of a heating, ventilation and air conditioning (HVAC) system for a vehicle.

[0002] Blower motors used in a vehicle's heating, ventilation, and air conditioning (HVAC) systems include electronics for controlling the motor. In a brushless DC motor, the electronics may include a printed circuit board (PCB) with power electronic components mounted on it, such as power circuit devices and capacitors. The motor electronics are generally housed within the blower motor casing or in a separate enclosure connected to the blower motor. The casing generally consists of two parts, with the PCB first mounted on a primary part and then a secondary casing part or cover attached to the primary part to enclose the PCBs and electronics. In KR10-2023-0123629, a control board is located in a space between an upper and a lower casing part.The control board is a printed circuit board-type structure installed on an inner upper surface of the lower housing. The control board may have a variety of holes that fit into protrusions formed on an inner surface of the lower housing.

[0003] The object of the present invention is to provide a blower motor device with an improved or alternative design for housing the electronics of a blower motor device.

[0004] According to a first aspect of the invention, this problem is achieved with a blower motor device for a heating, ventilation and air conditioning system of a vehicle, comprising: - an electronics enclosure containing electronic components mounted on a printed circuit board, - a stator comprising a stack of axially stacked steel sheets and a plurality of circumferentially spaced winding coils, - wherein the stator is connected to the electronics housing and is rotationally fixed with respect to the electronics housing, - wherein the electronics housing comprises an overmolded plastic material that is overmolded around the circuit board and electronic components.

[0005] Since the electronics housing is formed by overmolding the circuit board and electronic components, these parts do not need to be mounted separately in a housing. Furthermore, the features for attaching the blower motor and / or fan wheel to the electronics housing can be integrated into the overmolding material during the overmolding process.

[0006] The electronics housing is preferably formed from a one-shot overmolding around the circuit board and the electronic components.

[0007] The electronics housing includes fastening means for attaching the blower motor device to an external support structure.

[0008] The fasteners can be in the form of a variety of mounting tabs, provided in the one-shot overmolding process. The eyelets can be attached to an external support structure via a screw or bolt, for example, through a hole or opening in the eyelet.

[0009] The stator is connected to the electronics housing by a metal stator carrier, which comprises a cylindrical section extending axially. The stator is supported by this cylindrical section, and the electronics housing is overmolded around a portion of this section. The stator carrier is therefore integrated into the electronics housing and does not require subsequent fastening with screws or other means.

[0010] Furthermore, a rotor can be provided to support a blower wheel, wherein the rotor has a rotor shaft which is supported by at least one bearing within the cylindrical section of the stator carrier.

[0011] In one embodiment, the stator support comprises a flange extending radially from the cylindrical section, with the electronics housing being overmolded onto the flange.

[0012] The electronic components mounted on the printed circuit board include power switching devices, and the flange and the printed circuit board extend in parallel planes. The flange preferably extends at least over the area of ​​the printed circuit board that includes the power switching devices.

[0013] The flange can be provided as an insert in an overmolding tool, allowing the printed circuit board to be placed on the flange and overmolded to form the electronics package. The flange also serves to dissipate heat generated in the electronic components to an airflow passing over a surface of the flange.

[0014] A first radially extending surface of the flange faces the stator and / or a fan wheel and is in direct contact with a fluid, in particular the airflow generated by a fan wheel. A second radially extending surface of the flange faces away from the stator and is overmolded by a radially extending housing wall of the electronics enclosure to dissipate heat from the enclosure.

[0015] At least one projection can be provided on the second radially extending surface of the flange, the projection directly contacting the printed circuit board (PCB) to maintain a predefined separation distance between the second radially extending surface of the flange and the PCB. Preferably, a plurality of circumferentially spaced projections are provided. The PCB with the electronic components can therefore be positioned on the flange of the stator carrier and subsequently overmolded to form the electronics housing, so that the overmolded material seals the PCB and the electronic components, and a minimal thickness of the molding material is used to optimize heat transfer from the power electronics to the flange. The thickness of the overmolded material is determined by the axial length of the projection.

[0016] Alternatively, at least one projection or surface-mounted component may be provided on the printed circuit board, wherein the projection or surface-mounted component contacts the second radially extending surface of the flange to maintain a predefined separation distance between the second radially extending surface of the flange and the printed circuit board.

[0017] The radially extending housing wall of the electronic enclosure, which extends between the printed circuit board and the flange, has a wall thickness W in the axial direction, preferably 0.1 mm ≤ W ≤ 5.0 mm and more preferably 0.2 mm ≤ W ≤ 0.3 mm. This thickness range has been shown to provide sufficient wetting of the printed circuit board to seal the board and the electronic components, while simultaneously allowing sufficient heat transfer through the overmolding material to the flange, which dissipates the heat generated by the electronic components.

[0018] The first radially extending surface of the flange can comprise a plurality of heat transfer projections, preferably in the form of ribs, rings, or pins. These projections transfer heat energy to the airflow generated by the rotation of the fan wheel. The projections also create turbulence in the boundary layer, thus increasing heat transfer. Alternatively or additionally, the first radially extending surface of the flange comprises a plurality of blind holes facing the stator or a fan wheel. The blind holes dampen the noise generated by the fan wheel by absorbing and dissipating sound energy. Preferably, a plurality of first blind holes with a first diameter and a plurality of second blind holes with a second diameter are provided to dampen noise of different frequencies.The blind holes are provided on the surface of the flange exposed to the airflow.

[0019] The flange can include at least one opening, wherein a conductor passes through the opening to connect a stator coil to the circuit board, wherein a passage through the opening is sealed by the overmolded electronics housing.

[0020] The electronics enclosure can advantageously include a socket provided during one-shot overmolding to connect a power supply to the electronic components within the enclosure.

[0021] The electronics enclosure can comprise a radially extending enclosure wall having a radially inner section and a radially outer section, with a circumferentially extending damper arranged between the radially inner section and the radially outer section. In this way, a damper is provided as part of the electronics enclosure wall to dampen vibrations.

[0022] In particular, it is not necessary to provide damping elements between a stator carrier and the electronics housing.

[0023] The circumferential direction is relative to the axial direction. The damper preferably extends circumferentially over 360 degrees. Alternatively, a plurality of pointed damper sections overlapping in the circumferential direction may be present.

[0024] The housing wall is preferably manufactured from a single piece of molded material. Therefore, the housing wall can be produced in a one-shot molding process.

[0025] In one embodiment, the damper has the form of a groove circumferential in the housing wall between the radially inner section and the radially outer section.

[0026] The groove preferably extends in a loop closed in the circumferential direction.

[0027] The groove can be formed as a U-shaped bend in the radially extending housing wall.

[0028] The groove can reduce the amplitude of vibrations transmitted between the stator mounting points of the electronics housing by absorbing the energy during the elastic deformation of the U-shaped bend.

[0029] The depth of the groove in the axial direction is preferably greater than the thickness of the housing wall adjacent to the groove.

[0030] The housing wall is made of a first material, and the groove can be filled with a second material, preferably rubber, that differs from the first and has damping properties. In this case, the rubber improves the damping effect of the groove. The second material can be overmolded over the first material.

[0031] In an alternative embodiment, instead of a groove, a layer of damping material, different from the primary housing wall material, is provided between the radially inner and radially outer sections of the housing wall. Thus, there is no direct contact between the inner and outer parts of the housing wall, so that the outer housing wall section is connected to the inner housing wall section only via the damping material, such as rubber. The damping layer can also be provided by overmolding the inner and outer housing wall sections. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The embodiments are now described only by way of example with reference to the attached drawings, in which: Fig. 1 a perspective view of a blower motor device according to the invention Fig. 2 a cross-sectional view of a blower motor device according to an embodiment of the invention Fig. 3 a perspective view of an electronics housing of the blower motor device according to an embodiment of the invention Fig. 4 a perspective view of a stator carrier of the blower motor device according to the invention Fig. 5 a perspective view of a stator carrier of the blower motor device according to the invention Fig. 6 a perspective view of a blower wheel of the blower motor device according to the invention Fig. 7 an enlarged section of the blower motor assembly of Fig. 2. Fig. 8 a cross-sectional view of a blower motor device according to an embodiment of the invention. DETAILED DESCRIPTION

[0033] Fig. 1 and Fig. Figure 2 shows a blower motor device 1 for a heating, ventilation and air conditioning (HVAC) system of a vehicle according to a first embodiment of the invention. The blower motor device 1 can be mounted in a housing (not shown) to direct the airflow to and from the blower wheel 2.

[0034] The blower motor device 1 comprises a rotor shaft 3 extending in the axial direction 4 for supporting the blower wheel 2. The rotor shaft 3 is rotatably mounted by a first roller bearing 10 and a second roller bearing 11. A motor stator 5 comprises a plurality of circumferentially spaced winding coils 6 arranged in axial slots provided in a stack of steel sheets 7. The steel sheets 7 are stacked in the axial direction 4.

[0035] A control unit 55 is provided to regulate the current in the plurality of stator winding coils 6. The control unit 55 comprises electronic components 8, for example, power switches and capacitors, which are mounted on a printed circuit board (PCB) 9. The electronic components 8 and the PCB 9 are housed in an electronics enclosure 12. The stator 5 is connected to the electronics enclosure 12 and is rotationally fixed with respect to the electronics enclosure 12.

[0036] The electronics housing 12 comprises a radially extending housing wall 13, which includes a radially inner section 14 and a radially outer section 15.

[0037] A circumferentially extending damper 16 is arranged between the radially inner section 14 and the radially outer section 15 of the housing wall 13. The damper is thus provided as part of the electronics housing wall 13 to dampen the vibrations transmitted via the rotor shaft 3. The circumferential direction is relative to the axial direction and is indicated by the arrow 17. In the embodiment shown, the damper 16 extends circumferentially over 360 degrees and forms a closed loop. However, other configurations of the damper integrated into the housing wall 13 would also be possible to achieve damping between radially inner and outer sections of the housing wall 13. For example, a plurality of pointed damper sections overlapping in the circumferential direction 17 could be present.

[0038] In the Fig. 1 and Fig. In the embodiment shown in Figure 2, the housing wall 13 is manufactured from a single piece of molded plastic material. The housing wall 13 with the damper 16 can therefore be produced in a single one-shot injection molding process, for example, by an injection molding or transfer molding process. The damper 16 has the form of a groove 18 circumferentially extending in the housing wall 13 between the radially inner section 14 and the radially outer section 15.

[0039] The groove 18 extends in a loop closed in the circumferential direction 17. As in Fig. Figure 7, which shows an enlarged section of the electronics housing 12 in the area of ​​the damper 16, illustrates that the groove 18 can be formed as a U-shaped bend in the radially extending housing wall 13. This bend imparts elasticity to the housing wall 13 in the radial direction. The material of the bend in the housing wall 13 can also absorb energy, thus providing a damping effect. The depth of the groove 18 in the axial direction 4 is greater than the thickness of the housing wall adjacent to the groove.

[0040] The housing wall 13 is made of a first material, and the groove 18 can be filled with a second material 19, different from the first material, which has damping properties. The second material 19 is preferably rubber. The rubber increases the absorbed energy and improves the damping provided by the groove 18. Preferably, the second material 19 is overmolded over the first material.

[0041] In Fig. Figure 8 shows an alternative embodiment in which, instead of a groove, a layer of damping material 20, which differs from the first material of the housing wall 13, is provided between the radially inner section 14 and a radially outer section 15 of the housing wall 13. Thus, there is no direct contact between the inner and outer sections 14, 15 of the housing wall 13, thereby improving the damping effect. The damping material is preferably rubber and can also be provided by overmolding the inner and outer housing wall sections 14, 15.

[0042] The electronics housing 13 includes fasteners 21 for attaching the blower motor assembly 1 to an external support structure (not shown). The fasteners are in the form of a plurality of mounting lugs 21 arranged radially outside the damper to prevent the transmission of vibrations from the rotor to the external support structure. These lugs 21 are provided in the same forming step as the housing wall.

[0043] The radially extending housing wall 13 of the electronics housing 12 further comprises a plurality of blind holes 22 facing the stator 5 or a fan wheel 2. The blind holes 22 dampen the noise generated by the fan wheel 2 by absorbing and dissipating sound energy. The blind holes 2 comprise a plurality of first blind holes 23 with a first diameter and a plurality of second blind holes 24 with a second, smaller diameter to attenuate noise of different frequencies. The blind holes are provided on the surface 25 of the housing wall exposed to the airflow.

[0044] The electronics housing 12 is overmolded around the printed circuit board 9 with the electronic components 8 mounted on it. In this way, the overmolded material of the printed circuit board (PCB) is used to provide damping characteristics for radial vibrations.

[0045] The electronic housing 12 is formed around the circuit board and electronic components in a one-shot molding process. Therefore, the PCB does not need to be mounted in an existing housing, which reduces the number of manufacturing steps. The electronic housing 12 comprises an overmolded plastic material.

[0046] The fasteners 21 are also provided in a one-shot overmolding process. The eyelets 21 can be attached to the outer support structure via a screw or bolt, for example through a hole 53 or an opening in the eyelet.

[0047] As from Fig. As can be seen in Figure 2, the stator 5 is arranged on a stator support 26 made of metal, preferably aluminum due to its good thermal conductivity. The stator support 26 comprises a cylindrical section 27 extending in the axial direction 4 and a flange 28 extending radially therefrom. The cylindrical section 27 extends in the axial direction 4 from each side of the flange 28, and the electronics housing 12 is attached to the stator support 26. The stator is supported by the cylindrical section 27.

[0048] The rotor shaft 3 is rotatably mounted in the stator carrier 26 by the first and second roller bearings 10, 11. A first radially extending surface 29 of the flange faces the stator 5 and / or a fan wheel 2 and is in direct contact with a fluid, in particular the airflow generated by the fan wheel 2. A second radially extending surface 30 of the flange 28 faces away from the stator 5 and is in contact with the radially extending housing wall 13 of the electronics housing 12 for heat dissipation. Through the contact of the second radially extending surface 30 of the flange 28 with the radially extending housing wall of the electronics housing 12, heat can be dissipated from the electronic components 8.Since the first radially extending surface 29 of the flange 28 faces the stator 5 and / or a fan wheel 2, heat can be transferred by radiation or conduction to an airflow passing over the second radially extending surface of the flange 28. The flange 28 extends over the area of ​​the printed circuit board (PCB) 9 that includes the power circuitry or capacitors. The size of the flange 28 is therefore dependent on the positioning of the electronic components. The heat-generating electronic components 8 are preferably arranged on the PCB at locations near the areas of the flange 28 where the largest cooling airflow generated by the fan wheel 2 is present.

[0049] The electronics housing 12 is connected to the flange 28 by overmolding onto the flange 28. Fig. Figure 2 shows that the electronics housing 12 is overmolded over the second radially extending surface 30 of the flange. To prevent the overmolded housing 12 from detaching from the flange 28, the flange 28 can be provided with a radially extending lip 31 (see Figure 2). Fig. 7) shall be provided with a flange extending radially into the housing material, thus axially securing the stator carrier 26 in the electronics housing 12. The flange 28 of the stator carrier is recessed into the electronics housing wall. The damper 16 is arranged radially outside the flange 28.

[0050] The radially extending housing wall 13 of the electronic housing 12 is overmolded onto the flange 28 and has a wall thickness W in the axial direction between the flange 28 and the printed circuit board, which is indicated by arrow 32, where 0.1 mm ≤ W ≤ 5.0 mm, preferably 0.2 mm ≤ W ≤ 0.3 mm. It has been shown that this thickness range allows sufficient wetting of the printed circuit board to seal the board and the electronic components, while simultaneously enabling a sufficient degree of heat transfer through the overmolded material to the flange 28, which dissipates the heat generated by the electronic components 8.

[0051] The electronics housing 12 is also overmolded around a portion of the cylindrical section 27 of the stator carrier 26 to ensure secure attachment of the stator carrier 26 within the electronics housing 12. The stator carrier 26 can be used as a fixture in the PCB overmolding process tooling, allowing the PCB to be mounted on the stator carrier 26 and subsequently overmolded to form the electronics housing 12. The stator 5 carrier is therefore integrated into the electronics housing and does not require subsequent fastening by screws or other means.

[0052] Fig. 4 and Fig. Figure 5 shows two views of the stator support 26, where in Fig. 4 the first radially extending surface 29 of the flange 28 and in Fig. 5. A second radially extending surface 30 of the flange 28, opposite the first surface, is visible. At least one projection 33 is provided on the second radially extending surface 29 of the flange 28, which faces the printed circuit board 9. In the embodiment shown, each projection 33 extends in an arc in the circumferential direction 17. The projection 33 can be used as a positioning aid for the printed circuit board 9. The electronic components 8 mounted on the printed circuit board 9 include power circuit devices, and the flange 28 and the printed circuit board 9 extend in parallel planes. The flange 28 extends at least over the area of ​​the printed circuit board 9 that includes the power circuit devices. The flange 28 can be provided as an insert or mounting in an overmolding tool, so that the printed circuit board 9 is placed on the flange 28 and overmolded to form the electronic housing 12.The flange 28 also serves to dissipate the heat generated in the electronic components 8 to an airflow that passes over a surface of the flange 28.

[0053] The projection 33 directly contacts the circuit board 9, maintaining a predefined separation distance 32 between the second radially extending surface of the flange 30 and the circuit board 9. The circuit board 9, with the electronic components 8, can therefore be positioned on the flange 28 of the stator carrier 26 and subsequently overmolded to form the electronics housing 12. The overmolded material seals the circuit board 9 and the electronic components 8, and a minimal thickness of the molding material is used to optimize heat transfer from the power electronics to the flange 28. The thickness W of the overmolded material is determined by the axial length of the projection 33.

[0054] Preferably, a plurality of circumferentially spaced projections 33 are provided.

[0055] Alternatively, at least one projection or surface-mounted component can be provided on the printed circuit board 9, wherein the projection or surface-mounted component contacts the second radially extending surface 29 of the flange to maintain a predefined separation distance between the second radially extending surface 29 of the flange 28 and the printed circuit board 9.

[0056] Similar to the blind holes 22 on the electronics housing 12, the first radially extending surface of the flange 29 comprises a plurality of blind holes 34 facing the stator 5 or the fan wheel 2. The blind holes 34 dampen the noise generated by the fan wheel 2 by absorbing and dissipating sound energy. Preferably, a plurality of first blind holes 34 with a first diameter and a plurality of second blind holes 34 with a second, larger diameter are provided to dampen noise of different frequencies. The blind holes 34 are provided on the surface of the flange 28 exposed to the airflow. Alternatively or additionally to blind holes 34, the first radially extending surface 29 of the flange 28 can comprise a plurality of heat transfer projections, preferably in the form of ribs, rings, or pins, to improve heat transfer to the airflow above the flange surface.These protrusions transfer heat energy to the airflow generated by the rotation of the fan wheel. The protrusions also create turbulence in the boundary layer, thus increasing heat transfer.

[0057] The flange 28 comprises at least one opening 35 or through-hole, wherein a conductor 36 in the form of a wire, cable, or pin passes through the opening 35 to connect a stator winding coil 6 to the circuit board 9 in the electronics housing 12. The passage through the opening 35 is sealed by the overmolding material of the electronics housing 12.

[0058] Fig. Figure 6 shows a rear view of the fan wheel 2, which includes the rotor shaft 3 extending in the axial direction 4. The fan wheel 2 has an annular permanent magnet 37 or an annular part made of magnetizable material and a steel ring 38 acting as a yoke, which is arranged radially outside the permanent magnet 37. The fan wheel 2 has a portion in the form of a hollow cylinder 39, which is open at a first axial end 40 to allow an airflow into the cylinder 29, wherein an outer edge 41 of the cylinder 29 is formed by a plurality of first radial blades 42 spaced apart around the circumference of the cylinder 39.

[0059] The blower wheel 2 further comprises a back wall 43 extending between the outer edge 41 of the cylinder 39 and the rotor shaft 3. A section of the back wall 44, extending radially between the shaft 3 and the steel ring 38, forms a hub 44 of the blower wheel 2. The steel ring 38, the permanent magnet 37, and the shaft 3 are overmolded in the back wall.

[0060] In one embodiment, the steel ring 38, the permanent magnet 37, and the shaft 3 are placed together in a mold and overmolded in one shot. By overmolding the steel ring 38, the permanent magnet 37, and the shaft 3 in the rear wheel, the motor rotor components are integrated into the fan wheel 2 and do not need to be assembled separately with the shaft 3. This eliminates the need for a press fit or other subsequent connection between the shaft 3 and the fan wheel 2, thus avoiding misalignment problems between the shaft 3 and the wheel 2 that can lead to unwanted vibrations and noise. The steel ring 38 forms a yoke around the permanent magnet 37, thereby providing mechanical stability to the fan wheel 2 and establishing a magnetic flux path.

[0061] The permanent magnet 37 has a series of inwardly directed magnetic poles of alternating plurality. If a ring made of magnetizable material is used, it can also be magnetized after overmolding to provide a series of inwardly directed magnetic poles of alternating plurality on an inner surface of the ring 37.

[0062] The hollow cylinder 39 with its multiple radial blades 42 can be a so-called squirrel-cage impeller with forward-curved blades 42; however, other blade designs are also possible. The hollow cylinder 39 and the rear wall 43 of the impeller 2 can be formed by a one-shot overmolding of the steel ring 38, the permanent magnet 37, and the shaft 3 with a plastic material. The plastic material can be, for example, a polyphenylene sulfide plastic (PPS plastic) or a thermoset and can also contain a metal powder, e.g., a ferrite powder, in a volume fraction of 5%–50% to suppress EMC noise. Alternatively, the hollow cylinder 39 and the rear wall 43 can be formed by a two-shot overmolding process.In this case, in a first step, the steel ring 38, the permanent magnet 37, and the shaft 3 are overmolded with a plastic material, and in a second overmolding step, the hub 44 of the fan wheel 2 is formed. The hollow cylinder 39 can therefore be made of a first plastic material, and the hub 44 of a second plastic material containing a magnetic filler. In this way, the wheel 2 can be manufactured to provide EMC shielding while simultaneously reducing the required amount of filler material. The overmolding can be carried out, for example, by transfer molding or injection molding.

[0063] In one embodiment, the hub 44 is at least partially coated with a metal layer to provide electromagnetic shielding. Since the metal layer or metal ink coating is applied only to the surface of the hub 44, effective shielding can be provided while minimizing costs.

[0064] As in Fig. 2, Fig. 7 and Fig. As can be seen in Figure 8, the hub 44 is pot-shaped and has a cylindrical wall section 45 and a radially extending wall section 46, wherein the steel ring and the permanent magnet are arranged radially inward of the cylindrical wall section 46, i.e., contained within the cylindrical wall section 46. The hub 44 comprises at least one, preferably a plurality of, openings 47 that allow axial airflow through the hub 44. The openings 47 are provided in the radially extending wall section 46.

[0065] In Fig. Figure 6 shows that the rear wall 43 of the fan wheel 2 has a plurality of second radial blades 48 projecting axially 4 from the wall 43. The second radial blades 48 comprise a radially inner edge 49 and a radially outer edge 50, the radially inner edge 49 being arranged radially within a radially inner surface of the steel ring 38 and preferably radially inward of a radially inner surface of the permanent magnet 37. The second radial blades 48 are curved and inclined backward. The backward inclination of the blades 48 allows a higher pressure differential across the blades to be achieved. The pressure differential generated by the blades 48 on the rotating fan wheel 2 causes air to be drawn axially through the openings 47 in the hub 44, so that it flows over the stator 5 and is then expelled radially outward through the blades 48.The generated airflow can therefore be used to cool parts of the stator that are arranged radially inwards of the magnet ring.

[0066] The arrangement of the second radial blades 48, which extend radially over the steel ring 38 and preferably radially over the magnet ring 37, serves to prevent any axial displacement of the steel ring 38 or the magnet ring 37 with respect to the overmolding material. The second radial blades 48 are overmolded in the same overmolding step as the hollow cylinder 39.

[0067] The airflow generated by the second radial blades 48 of the blower wheel 2 also flows over the first radially extending surface of the flange 28 to cool the flange and the electronic components 8.

[0068] At least a radially outer portion of the first radially extending surface of the flange 28 faces directly towards a fan wheel 2. The flange 28 therefore extends radially such that it is at least partially axially opposite the fan wheel 2. The flange 28 can therefore extend radially up to a radius R1 that is larger than the outer radius of the steel plates 7 of the stator 5.

[0069] The plurality of second radial blades 48 are located opposite the first radially extending surface 29 of the flange 28, and each blade 48 has an axially oriented end surface 51 that points towards the flange 28. A gap 52 is formed between the end surface 51 and the first radially extending surface of the flange, the gap preferably having a width d in the range of 0.1 mm ≤ W ≤ 5.0 mm, more preferably 0.3 mm ≤ W ≤ 0.7 mm. This arrangement of the blades 48 near the flange 28 improves heat dissipation from the flange and cooling of the electronic components due to the increased pressure differential created by the small gap 52 across the blades.

[0070] With renewed reference to Fig.2. It can be stated that the electronics housing 12 is formed by overmolding the circuit board 9 and the electronic components 8, and therefore these parts do not need to be mounted separately in a housing 12. Furthermore, the features for attaching the blower motor and / or the blower wheel 2 to the electronics housing 12 can be integrated into the overmolding material in the overmolding step(s).

[0071] The electronics housing 12 can further include a socket 54, which is provided during the one-shot overmolding of the circuit board 9, to connect a power supply to the electronic components 8 in the electronics housing 12. List of reference symbols 1 blower motor device 2 blower wheel 3 Rotor shaft 4 Axial direction 5 Stator 6 winding coils 7 steel sheets 8 electronic components 9 printed circuit board 10 roller bearings 11 roller bearings 12 electronic housings 13 Housing wall 14 Radial inner housing wall 15 Radial outer housing wall 16 dampers 17 Circumferential direction 18 Nut 19 Second material 20 damping layer 21 fastening eyelets 22 blind holes 23 First dead ends 24 Second blind holes 25 surface 26 Stator carriers 27 Cylindrical section 28 flange 29 First surface of the flange 30 Second surface of the flange 31 Lippe 32 Wall thickness W 33 lead 34 blind holes 35 Opening 36 ladders 37 Magnet 38 steel ring 39 hollow cylinders 40 First axial end 41 edge 42 shovels 43 Back panel 44 hub 45 Cylindrical wall 46 Wall section 47 openings 48 Second shovels 49 Inner shovel edge 50 Outer shovel edge 51 Final surface 52 columns 53 holes 54 socket 55 Control unit QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] KR 10-2023-0123629

[0002]

Claims

[1] Blower motor device (1) for a heating, ventilation and air conditioning system of a vehicle, comprising: - an electronic housing (12) containing 9 electronic components (8) mounted on a circuit board, - a stator (5) comprising a stack of steel sheets (7) stacked in the axial direction (4) and a plurality of winding coils (6) spaced apart in the circumferential direction 17, - wherein the stator (5) is connected to the electronic housing (12) and is rotationally fixed with respect to the electronic housing (12), - wherein the electronic housing (12) comprises an overmolded plastic material which is overmolded around the circuit board (9) and the electronic components (8). [2] Blower motor device (1) according to claim 1, characterized by , that the electronic housing (12) is formed by a one-shot overmolding around the circuit board (9) and the electronic components (8). [3] Blower motor device (1) according to claim 1, characterized by, that the electronics housing (12) includes fastening means (21) for attaching the blower motor device (1) to an external support structure. [4] Blower motor device (1) according to claim 2, characterized by , that the fastening means (21) is in the form of a plurality of fastening tabs (21) which are provided in the one-shot overmolding. [5] Blower motor device (1) according to one of the preceding claims, characterized by , that the stator (5) is connected to the electronics housing (12) via a metal stator carrier (26), wherein the stator carrier (26) comprises a cylindrical section (27) extending in the axial direction (4), wherein the stator (5) is supported by the cylindrical section (27) and the electronics housing (12) is overmolded around part of the cylindrical section (27). [6] Blower motor device (1) according to claim 5, characterized by, that a rotor is provided for supporting a blower wheel, with a rotor shaft (3) which is supported by at least one bearing (10), (11) within the cylindrical section (27) of the stator carrier (26). [7] Blower motor device (1) according to one of the preceding claims, characterized by , that the stator carrier (26) comprises a flange (28) extending radially from the cylindrical section (27), the electronics housing (12) being overmolded onto the flange (28). [8] Blower motor device (1) according to claim 7, characterized by , that the electronic components (8) mounted on the printed circuit board (9) comprise power switching devices, wherein the flange (28) and the printed circuit board (9) extend in parallel planes and the flange (28) extends at least over the area of ​​the printed circuit board (9) which comprises the power switching devices. [9] Blower motor device (1) according to claim 7, characterized by, that a first radially extending surface (29) of the flange (28) faces the stator (5) and / or a blower wheel (2) and is in direct contact with a fluid, and a second radially extending surface (30) of the flange (28) faces away from the stator (5) and is overmolded for heat dissipation from the electronics housing (12) by a radially extending housing wall (13) of the electronics housing (12). [10] Blower motor device (1) according to claim 9, characterized by , that at least one projection (33) is provided on the second radially extending surface (30) of the flange (28), wherein the projection (33) directly contacts the printed circuit board (9) in order to maintain a predefined separation distance between the second radially extending surface (30) of the flange (28) and the printed circuit board (9). [11] Blower motor device (1) according to claim 9, characterized by, that at least one projection or surface-mounted component is provided on the printed circuit board (9), wherein the projection or surface-mounted component contacts the second radially extending surface (30) of the flange (28) in order to maintain a predefined separation distance between the second radially extending surface (30) of the flange (28) and the printed circuit board (9). [12] Blower motor device (1) according to claim 9, characterized by , that the radially extending housing wall (13) of the electronic housing (12), which extends between the circuit board (9) and the flange (28), has a wall thickness W in the axial direction (4), wherein 0.1 mm ≤ W ≤ 5.0 mm, preferably 0.2 mm ≤ W ≤ 0.3 mm. [13] Blower motor device (1) according to any one of claims 7 to 12, characterized by, that the first radially extending surface (29) of the flange (28) comprises a plurality of heat transfer projections, preferably in the form of ribs or rings or pins. [14] Blower motor device according to any one of claims 7 to 13, characterized by , that the first radially extending surface (29) of the flange (28) comprises a plurality of blind holes (34). [15] Blower motor device (1) according to any one of claims 7 to 14, characterized by , that the flange (28) includes at least one opening (35) wherein a conductor (36) passes through the opening (35) to connect a stator coil (6) to the circuit board (9), wherein a passage through the opening (35) is sealed by the overmolded electronic housing (12).

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