Motor Insulator Wire Guide for Soldering Access
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Solution Overview
Problem
Existing motor manufacturing methods face challenges with electric wire tension variability leading to deformation or damage, and difficulty in soldering due to close proximity of components, which increases the risk of wire contact with the circuit board edges.
Innovation Solution
A motor design featuring a resin insulator with a wire guide portion that positions the electric wire's drawn-out portion below the circuit board's surface, reducing contact risk and tension by moving the circuit board downward after soldering, thus preventing damage and facilitating the soldering process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electric wire is wound around a pin-shaped terminal, then electrical connection is achieved, but the tension of the wound electric wire varies depending on the operator, leading to deformation of the terminal or damage of the electric wire
Solution Approach 1:
The patent introduces a resin insulator with a through-hole as an intermediary component between the terminal and the circuit board. The electric wire is inserted through this through-hole, which serves as a guiding structure that standardizes the wire's path and positioning. This intermediary structure eliminates the need for manual winding around pin-shaped terminals, thereby ensuring consistent wire tension and positioning while maintaining reliable electrical connection.
2Reliability
If the electric wire is soldered to the upper surface of the circuit board, then electrical connection is established, but the soldering operation becomes difficult due to close proximity of the stator and circuit board
Solution Approach 1:
Instead of soldering the electric wire to the upper surface of the circuit board, the patent inverts the approach by having the wire pass through a through-hole in the resin insulator and be soldered to a land portion on the lower surface of the circuit board. This inversion of the soldering location eliminates the interference from the stator, making the soldering operation accessible and easy to perform while maintaining reliable electrical connection.
3Reliability
If the electric wire is drawn out beyond the lower surface of the circuit board, then connection to the land portion is achieved, but the electric wire easily makes contact with the edge of the circuit board, causing damage or breaking
Solution Approach 1:
The resin insulator with a through-hole serves as a protective intermediary structure. The electric wire passes through this through-hole, which is positioned such that the wire is guided away from the edge of the circuit board. This intermediary structure physically protects the wire from contacting the circuit board edge, preventing damage or breaking while maintaining the necessary electrical connection to the land portion.
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 effectively reduces the likelihood of electric wire damage and simplifies the soldering operation by positioning the contact area below the circuit board's surface, minimizing tension and preventing contact with edges, thereby enhancing manufacturing efficiency and reliability.
Implementation Method 1
soldering the drawn-out portion to the land portion
Data Source
AI summary
An insulator of a motor includes a body portion and a wire guide portion. The body portion is arranged to cover an upper surface, a lower surface, and circumferential side surfaces of each of a plurality of teeth. The wire guide portion is arranged to project downward from the body portion. A drawn-out portion of an electric wire which extends from a coil is arranged to reach a land portion arranged on a lower surface of a circuit board after passing through the wire guide portion. In addition, an area of contact between the drawn-out portion and the wire guide portion is arranged at an axial height lower than that of the lower surface of the circuit board.