Motor PCB Fixation Using Integrated Spring-Seal Insulation
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Solution Overview
Problem
Existing methods for fixing printed circuit boards in electric motors, such as adhesive bonding and screwing, are time-consuming and hinder automated production, while gap fillers do not effectively hold down the boards.
Innovation Solution
A two-component injection-molded insulation part with a hard and soft component, incorporating a spring element and hold-down means, provides a mechanical fixation that allows for automated assembly and sealing without additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive bonding or screwing methods are used to fix printed circuit boards, then reliable mechanical fixation is achieved, but production time increases and automated production is hindered
Solution Approach 1:
The patent combines the sealing function (gap pad) and the mechanical fixation function (hold-down means) into a single integrated insulation part. This merging eliminates the need for separate adhesive bonding or screwing operations, enabling automated production while maintaining reliable mechanical fixation of the printed circuit board.
Solution Approach 2:
The insulation part serves multiple functions simultaneously: it provides electrical insulation, seals gaps between components, and mechanically holds down the printed circuit board through its integrated hold-down means. This multi-functionality resolves the contradiction by consolidating fixation and sealing into one component that can be installed automatically.
2Ease of manufacture
If gap fillers are used instead of gap pads, then automated application is possible, but the ability to hold down printed circuit boards is lost
Solution Approach 1:
The patent merges the gap filler material with a hold-down means into an integrated insulation part. The soft component part provides the gap-filling sealing function while the hard component part with its hold-down means provides the mechanical retention capability. This combination enables both automated application and effective holding down of the printed circuit board.
Solution Approach 2:
The insulation part is constructed as a composite of a soft component part (providing sealing and gap-filling properties) and a hard component part with hold-down means (providing structural support and mechanical fixation). This composite structure resolves the contradiction by combining materials with complementary properties that enable both automated application and reliable holding down.
3Reliability
If separate gap pads and hold-down components are used, then functional requirements are met, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent merges the gap pad and the hold-down component into a single integrated insulation part. This reduces the number of separate components and assembly steps while maintaining both the sealing function and the mechanical fixation function, thereby reducing device complexity and manufacturing costs.
Solution Approach 2:
The insulation part is designed as a multi-functional component that simultaneously provides electrical insulation, gap sealing, and mechanical hold-down capability. This universality eliminates the need for multiple separate components, simplifying the overall device structure and reducing manufacturing complexity.
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
Enables rapid, cost-effective, and automated production of printed circuit board fixation in electric motors, ensuring stable holding and sealing while minimizing additional steps and costs.
Implementation Method 1
the insulation part comprises at least one spring element for exerting a pressing force on the first housing part
Data Source
AI summary
An apparatus for fixing a printed circuit board within a housing of an electric motor, comprising a first housing part, a second housing part, and an insulation part. The insulation part is arranged between the first housing part and the second housing part, such that the housing parts are spaced apart from one another at least in certain portions by the insulation part, including a hard component part and a soft component part. The insulation part comprises at least one spring element for exerting a pressing force on the first housing part. The hard component part comprises at least one hold-down means, having at least one pressure-exerting element. The soft component part is configured to provide a seal between the housing parts. The spring element is arranged on that side of the insulation part which lies opposite to a stop region in the direction of the holding force.