Brushless Motor Heat Sink Shielding Circuit Board
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional brushless DC motors have structural design issues that make them difficult to assemble, disassemble, and repair, and their electronic components on circuit boards are exposed and prone to damage or short-circuiting.
Innovation Solution
A brushless motor assembly design that incorporates a heat sink between the motor body and circuit board, which serves as a heat dissipator, support, and protector for the electronic components by shielding them and facilitating assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electronic components are exposed on the circuit board for easy access and installation, then ease of manufacture is improved, but reliability deteriorates due to collision damage and short-circuiting
Solution Approach 1:
The circuit board is nested within the hollow cavity of the heat sink, which encloses and protects the electronic components. This nesting structure allows the heat sink to serve as both a thermal management device and a protective housing for the circuit board, resolving the contradiction between accessibility and protection.
Solution Approach 2:
The heat sink acts as an intermediary structure between the motor body and the circuit board. It provides a protective barrier that shields electronic components from external damage while maintaining thermal contact for heat dissipation, thus protecting components without completely isolating them.
2Temperature
If the heat sink is designed to dissipate heat effectively, then temperature control is improved, but device complexity increases due to additional structural requirements
Solution Approach 1:
The heat sink is designed to perform multiple functions simultaneously: heat dissipation through its finned structure, mechanical support for the circuit board via its hollow cavity, and physical protection of electronic components. This multi-functionality reduces the need for separate protective structures, thereby managing complexity while achieving temperature control.
Solution Approach 2:
The protective housing function and heat dissipation function are merged into a single component - the heat sink. By combining these functions, the patent avoids adding separate protective enclosures that would increase complexity, instead making the existing heat sink serve dual purposes.
3Productivity
If the motor assembly is designed for compact space utilization, then productivity is improved, but ease of repair deteriorates due to difficult disassembly
Solution Approach 1:
The motor assembly is segmented into distinct modular components: motor body, heat sink with embedded circuit board, and end covers. These modules are connected through standardized mounting structures that allow for easy separation and reassembly, facilitating repair while maintaining compact overall dimensions.
Solution Approach 2:
The assembly uses dynamic fastening mechanisms (screws or clips) that allow for easy assembly and disassembly. The heat sink can be detached from the motor body, and the circuit board can be accessed by removing the heat sink, enabling repair operations without permanently fixed structures.
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 heat sink effectively dissipates heat from the motor control unit and power switch, protects electronic components, and optimizes assembly space while allowing for easy assembly and maintenance by shielding the circuit board and providing a secure mounting solution.
Implementation Method 1
the heat sink has a first side portion and a second side portion which are opposite to each other; the first side portion faces the motor body, and the second side portion faces the circuit board
Implementation Method 2
the heat sink effectively dissipates heat from the motor control unit and power switch
Data Source
AI summary
A brushless motor assembly includes a motor body, a circuit board, and a heat sink. The circuit board has a mounting surface and includes a motor control unit and a power switch which are disposed on the mounting surface. The motor control unit is adapted to control an operation of the power switch. The heat sink is disposed between the motor body and the circuit board, wherein the heat sink has a first side portion and a second side portion which are opposite to each other; the first side portion faces the motor body, and the second side portion faces the circuit board and shields the mounting surface of the circuit board. With the aforementioned design, it could effectively protect the electronic components on the circuit board and provide good heat dissipation effect.