Vehicle Blower Motor PCB Terminal for Heat and Vibration Stability
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Solution Overview
Problem
Conventional BLDC-type blower motors face issues with poor electrical contact and heat radiation performance due to direct connection of stator phase terminals to PCB boards, leading to potential short circuits and increased manufacturing costs.
Innovation Solution
A blower motor design featuring a U-shaped PCB terminal with elastic clamping and a heat-conducting double-sided adhesive tape for improved electrical connection and heat radiation, using a rotor module, stator module, and a lower housing as a heat sink.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If stator phase terminals are directly connected to PCB boards, then electrical connection is simple, but short circuits may occur due to external shocks or vibrations
Solution Approach 1:
A PCB terminal is introduced as an intermediary component between the stator phase terminal and the PCB board. This PCB terminal includes a clamp portion that elastically clamps the stator phase terminal, providing a stable electrical connection that resists external shocks and vibrations while maintaining connection reliability
Solution Approach 2:
The PCB terminal utilizes elastic deformation through its clamp portion to dynamically adapt to connection forces. The elastic clamping mechanism allows the terminal to maintain stable contact under varying mechanical conditions, including external shocks and vibrations, thereby improving connection reliability without excessive complexity
2Reliability
If PCB terminals are used to connect stator phase terminals, then electrical insulation is improved, but manufacturing cost increases due to complex structure
Solution Approach 1:
The PCB terminal is formed from a single plate through bending processes that create the U-shaped structure with clamp portions. This parameter change from flat plate to three-dimensional clamping structure provides electrical insulation and mechanical stability while maintaining manufacturing simplicity and cost-effectiveness
Solution Approach 2:
The PCB terminal features an asymmetric U-shaped design with specifically positioned clamp portions that provide both electrical insulation and mechanical clamping functions. This asymmetric structure is optimized for its specific function rather than being a symmetric complex assembly, thereby reducing manufacturing costs while improving reliability
3Temperature
If PCB boards are mounted on lower housing, then heat radiation can be improved, but mounting complexity increases
Solution Approach 1:
The mounting structure merges multiple functions into a single integrated design. The lower housing structure combines mechanical support for the PCB board with heat radiation functionality, eliminating the need for separate mounting brackets or heat sinks. This reduces mounting complexity while improving heat radiation performance through direct thermal coupling
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
Enhances electrical insulation and heat radiation performance while reducing the risk of poor contact and manufacturing costs, ensuring stable operation and efficient heat dissipation.
Implementation Method 1
a heat-conducting double-sided adhesive tape for improved electrical connection and heat radiation
Implementation Method 2
a U-shaped PCB terminal with elastic clamping
Implementation Method 3
using a rotor module, stator module, and a lower housing as a heat sink
Data Source
AI summary
A blower motor for a vehicle includes: a rotor module and a stator module; a lower housing on which the rotor module and the stator module are mounted; a PCB board mounted on a lower surface of the lower housing; a stator phase terminal protruding downward from the stator module and supplying electricity to the stator module; and a PCB terminal coupled to at least a portion of the stator phase terminal to supply power to the stator module. The PCB terminal is formed by bending a single plate into a “U” shape.