Motor Choke Coil Positioning via Iron Core Projections

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Solution Overview

Problem

The existing motor designs face challenges in maintaining the positional stability of the choke coil, leading to potential displacement and connection failures due to flexible pig tails and lead wires, which increases the number of components and assembly steps.

Innovation Solution

Incorporating an iron core with projecting portions into the choke coil, which is held by a power supplying terminal with higher rigidity, ensuring secure connections and reducing the likelihood of displacement by anchoring the choke coil at multiple points.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the choke coil is connected using flexible pig tail and lead wire, then electrical connection is achieved, but the choke coil position becomes unstable and prone to displacement

Engineering Contradiction:

Improveelectrical connectionVSAvoidchoke coil position

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The iron core is segmented into a coil portion and a projecting portion, where the projecting portion serves as a dedicated positioning element that extends beyond the coil portion to engage with the brush holder, thereby separating the electrical connection function from the positioning function

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The projecting portion of the iron core acts as an intermediary element between the choke coil and the brush holder, providing a stable mechanical connection point that prevents displacement while allowing the flexible pig tail and lead wire to maintain electrical connection

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If a dedicated fixing member is used to connect the choke coil, then the choke coil position is stabilized, but the number of components and assembly steps increases

Engineering Contradiction:

Improvechoke coil positionVSAvoidnumber of components

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The iron core merges multiple functions into a single component: it provides magnetic flux path, electrical connection terminal, and mechanical positioning feature through its projecting portion, eliminating the need for separate fixing members

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The iron core is designed as a multi-functional element that simultaneously serves as the magnetic core, electrical terminal, and positioning structure, thereby reducing the overall component count while maintaining stability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS9583995B2Motor

Publication Date: 2017.02.28 DENSO CORP

AI summary

A motor includes a power supplying brush, a brush holder, a choke coil, and a power supplying terminal. The brush holder holds the power supplying brush. The choke coil includes a coil portion having a coil shape, an iron core, a first connecting portion, and a second connecting portion. The iron core is inserted into the coil portion. The iron core is longer than an axial length of the coil portion. The iron core has a projecting portion projecting from the coil portion in an axial direction of the coil portion. The first connecting portion extends from an axial first end of the coil portion. The second connecting portion extends from an axial second end of the coil portion. The power supplying terminal is assembled to the brush holder. The power supplying terminal connects with at least one of the first connecting portion and the second connecting portion. At least one of the power supplying terminal and the brush holder includes an iron core holding portion that holds the projecting portion.