Motor Connector Unit Segmentation for Simplified Wiper Motor Assembly
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Solution Overview
Problem
The manufacturing process of wiper motors is complex due to the need for multiple sliding molds to embed bent internal wirings in the brush holder, making it difficult to simplify the process while maintaining electrical insulation and connectivity.
Innovation Solution
A motor apparatus with a connector unit that includes a base portion, a connector connecting portion, and conductive members with specific arrangements and attachments, allowing for simplified assembly by reducing the number of molds required and improving the positioning of conductive members for easier integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple sliding molds are used to embed bent internal wirings in the brush holder, then electrical insulation and connectivity are maintained, but the manufacturing process becomes complex
Solution Approach 1:
The patent divides the brush holder into multiple sections, each capable of being molded independently. This segmentation allows different conductive members to be embedded in separate molding operations rather than requiring multiple sliding molds in a single complex operation, thereby simplifying the manufacturing process while maintaining electrical insulation and connectivity
Solution Approach 2:
The patent positions conductive members in predetermined locations before the molding process. By pre-positioning these conductive members and then molding the brush holder around them in simpler, sequential operations, the need for complex multi-sliding mold operations is eliminated, reducing manufacturing complexity while ensuring proper electrical connections
2Reliability
If bent internal wirings are embedded in the brush holder by insert molding, then electrical connectivity is achieved, but the number of molds required increases
Solution Approach 1:
The brush holder is divided into multiple moldable sections that can be produced using simpler single-slide or progressive molds rather than requiring multiple complex sliding molds. This segmentation allows electrical connectivity to be achieved through sequential molding operations with fewer, simpler mold types
Solution Approach 2:
The patent designs the mold system to be multi-functional, where a single mold or mold set can produce different sections of the brush holder with different conductive members embedded. This universal mold design reduces the total number of specialized molds required while maintaining proper electrical connectivity
Data Source
AI summary
A motor apparatus provided with a connector unit (40) to which an external connector is connected, wherein the connector unit (40) has a plurality of conductive members (64, 65, 66) arranged over a base portion (50) and a connector connecting portion (70) provided with a plug-in hole in which the external connector is plugged, wherein the conductive members (64, 65, 66) respectively include connector-side connecting portions (64a, 65a, 66a) connected to the external connector so as to face the connector connecting portion (70) from a first direction reversed to a plug-in direction of the external connector to the plug-in hole and base-side connecting portions (64b, 65b, 66b) connected to terminals or wirings provided in the base portion (50), wherein the connector-side connecting portions (64a, 65a, 66a) are respectively inserted into a plurality of insertion holes (74, 75, 76) provided at positions different from each other in a second direction intersecting the first direction, and wherein the base-side connecting portions (64b, 65b, 66b) are respectively arranged at the same position in the second direction.