Brush Assembly Mount with Adhesive Containment Recesses
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Solution Overview
Problem
Excess adhesive contamination on the stator body of electric motors interferes with the assembly of brush assemblies and end caps, causing surface attachment issues and warping, which increases motor tolerances and complicates the assembly process.
Innovation Solution
The brush assembly and end cap are designed with integrated posts and recessed surfaces that align with areas between magnet segments, allowing excess adhesive to be contained and preventing interference with the assembly, while fasteners secure the components together.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is applied to attach magnets to the stator body, then the magnets are securely fixed, but excess adhesive contaminates the stator body surface and interferes with brush assembly attachment
Solution Approach 1:
The patent converts the harmful effect of excess adhesive by providing recesses in the stator body that specifically receive and contain the excess adhesive. Instead of allowing the adhesive to contaminate critical surfaces, the recesses provide a designated space for it, transforming the contamination problem into a controlled containment solution that prevents interference with brush assembly attachment.
Solution Approach 2:
The recesses act as an intermediary structure between the adhesive application process and the brush assembly attachment. By providing this intermediate containment space, the recesses mediate the interaction between excess adhesive and the stator body surface, preventing direct contact between the adhesive and the brush assembly mounting areas.
2Strength
If excess adhesive is present on the stator body, then magnet attachment is ensured, but assembly precision decreases due to surface contamination and warping
Solution Approach 1:
The recesses transform the harmful excess adhesive into a contained element that does not compromise assembly precision. By providing a specific receptacle for the adhesive, the design ensures that even with generous adhesive application, the precision surfaces remain clean and the assembly maintains tight tolerances.
3Ease of manufacture
If traditional brush assembly mounting is used without adhesive containment features, then assembly is simpler, but adhesive contamination causes warping and attachment failures
Solution Approach 1:
The recesses provide a simple geometric feature that reliably contains adhesive without complicating the manufacturing process. The recesses can be easily formed during stator production, and they provide robust adhesive containment that prevents warping and ensures reliable brush assembly attachment.
Solution Approach 2:
The recesses provide self-contained adhesive management that does not require additional complex mechanisms. The geometry of the recesses naturally contains the adhesive through their shape alone, providing self-service adhesive containment that improves reliability without adding manufacturing complexity.
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
This design ensures proper alignment and assembly of the motor components, preventing adhesive-related issues and maintaining motor precision by containing excess adhesive between posts, thus enhancing the assembly process and reducing motor tolerances.
Implementation Method 1
a plurality of magnets attached to an inner surface of the stator body via an adhesive
Data Source
AI summary
An electric motor is provided including a stator assembly having a stator body and magnets attached to an inner surface of the stator body via an adhesive, and an armature rotatably received within the stator assembly and having an armature shaft on which a commutator is mounted. A brush assembly is provided including a brush card mount disposed around the commutator and a mating housing longitudinally extending from the brush card mount. The mating housing includes a cylindrical wall and a mating surface formed substantially perpendicularly to an inner surface of the cylindrical wall and arranged to mate with an end surface of the stator body. The mating surface of the mating housing includes posts longitudinally extending along the inner surface of the cylindrical wall and recessed surfaces formed therebetween, the posts being mounted on the end surface of the stator body.