BLDC Motor Housing with Pin Guide for PCB Protection
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Solution Overview
Problem
Conventional BLDC motors with BMC resin housings face issues such as damage to printed circuit boards during insert injection molding, leading to increased manufacturing costs and complex assembly processes due to high temperature conditions and integrated circuit device damage.
Innovation Solution
A motor design where the stator assembly is molded within a housing with exposed power terminal pins, a printed circuit board with a shaft insertion hole and power terminal pin holes, and an end cover for easy assembly and heat radiation, allowing for separate assembly and reduced risk of damage during resin molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If insert injection molding is performed with the printed circuit board disposed on the stator, then the housing is molded together with the stator and printed circuit board, but the devices mounted on the printed circuit board are broken or damaged due to high temperature conditions
Solution Approach 1:
The manufacturing process is divided into separate stages: first molding the housing with the stator, then separately assembling the printed circuit board and radiation plate onto the stator outside the mold. This segmentation prevents the printed circuit board from being exposed to high temperatures during injection molding while maintaining the integrated housing structure.
Solution Approach 2:
The printed circuit board is prepared and the radiation plate is mounted on the stator before the housing molding process. By performing these assembly operations in advance, the printed circuit board and its sensitive devices are protected from the high temperature conditions during injection molding.
2Reliability
If the radiation plate is mounted after the printed circuit board electrical connection is finished, then heat radiation is enabled, but the assembly work becomes difficult and the manufacturing process becomes complicated
Solution Approach 1:
The radiation plate is mounted on the stator together with the printed circuit board in a preliminary assembly step before housing molding. This preliminary action simplifies the overall manufacturing process by consolidating multiple components into one assembly operation, eliminating the need for complex post-molding assembly operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design facilitates easy assembly, reduces manufacturing costs, and enhances heat radiation efficiency by preventing printed circuit board damage and simplifying the assembly process while maintaining structural integrity.
Implementation Method 1
the injection is performed with the BMC resin to make a housing
Implementation Method 2
the injection molding work is carried out on relatively high temperature conditions
Implementation Method 3
a thermal conductor disposed on the top of the integrated circuit device, the thermal conductor having a height capable of being brought into contact with the end cover
Implementation Method 4
a radiation plate for radiating the heat generated from an integrated circuit device
Data Source
AI summary
The present invention relates to a motor including: a housing formed in such a manner as to locate a stator assembly inside a mold and to perform an insert injection molding, the housing having a hollow portion formed at the inside thereof and power terminal pins exposed above the hollow portion; a printed circuit board adapted to mount an integrated circuit device thereon and having a shaft insertion hole formed at the center thereof and power terminal pin holes formed at the corresponding positions to the power terminal pins; and an end cover adapted to be coupled to the housing in such a manner as to be located on the top of the printed circuit board and having a motor shaft coupling portion formed at the center thereof.