Injection-Molded Motor Frame With Integrated Circuit Insert
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Solution Overview
Problem
The manufacturing process of motor frames for optical instrument actuators is complex, leading to long manufacturing times, high assembly error rates, and increased costs due to quality issues such as strength reduction and deformation of the motor base.
Innovation Solution
A motor frame design that integrates a conductive circuit member with a frame body through injection molding, eliminating the need for assembly tolerances and allowing for the protection of electronic components during high-temperature molding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the motor base is molded into a complete form and electronic components are assembled by welding or bonding, then the structural integrity is improved, but the manufacturing process becomes complicated and manufacturing time increases
Solution Approach 1:
The patent combines multiple separate manufacturing steps (molding the motor base, assembling coils, mounting circuit boards, and making electrical connections) into a single integrated injection molding process. The circuit board and coils are pre-assembled as an insert that is directly embedded into the motor base during injection molding, eliminating the need for separate welding or bonding operations and significantly simplifying the manufacturing process.
2Reliability
If multiple assembly processes are used to attach coils and circuit boards, then the electrical connections are established, but the assembly error rate and defect rate accumulate
Solution Approach 1:
The patent merges the electrical connection process with the structural assembly process by integrating the circuit board and coils as an insert that is directly embedded into the motor base during injection molding. This single-step integration eliminates multiple separate assembly operations, thereby preventing the accumulation of assembly errors and defects across multiple processes.
3Shape
If the motor base is molded first and then components are attached, then the base structure is formed, but strength reduction or deformation during molding affects subsequent attachment processes
Solution Approach 1:
The patent applies preliminary action by pre-assembling the circuit board and coils as an integrated insert before the injection molding process. This allows the motor base to be molded with the insert already in position, ensuring proper alignment and preventing deformation issues that would occur if components were attached after molding. The insert is designed to withstand the injection molding conditions and maintain its structural integrity throughout the process.
4Ease of manufacture
If separate assembly processes are used for coils and circuit boards, then the components are mounted, but productivity is reduced and manufacturing cost increases
Solution Approach 1:
The patent merges multiple discrete manufacturing operations into a single injection molding process. The circuit board and coils are prepared as a pre-assembled insert, which is then directly embedded into the motor base during injection molding. This eliminates the need for separate mounting processes, significantly improving productivity and reducing manufacturing costs by reducing the number of process steps, handling operations, and quality inspections required.
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 approach simplifies the manufacturing process, improves quality by eliminating assembly errors, and reduces production costs by enabling higher-temperature injection molding without damaging electronic components.
Implementation Method 1
a frame body injection-molded by inserting a conductive circuit member forming a circuit pattern electrically connected to an electronic component including the coil
Data Source
AI summary
The present invention relates to a motor frame applied to an optical instrument actuator in which a coil is disposed in the magnetic field of a magnet. The motor frame applied to the optical instrument actuator of the present invention includes a frame body injection-molded by inserting a conductive circuit member forming a circuit pattern electrically connected to an electronic component including the coil.