Motor Substrate Recess Layout for Cleaner Coil Connections
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Solution Overview
Problem
Existing motors face challenges in manufacturing efficiency due to complex connections between conductors and substrates, which can be hindered by foreign matter entering critical spaces and affecting performance.
Innovation Solution
A motor design featuring a substrate with recessed parts and protruding parts that guide conductors through gaps, ensuring secure electrical connections while preventing foreign matter intrusion, and utilizing elastic members for precise positioning and tensioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductors are connected to lands on the substrate using conductive members, then electrical connection is achieved, but foreign matter may enter the connection space and affect performance
Solution Approach 1:
The substrate is divided into distinct functional regions: a connection region for electrical connections and a nonconnection region for other components. This segmentation isolates the electrical connection space, preventing foreign matter from entering while maintaining reliable electrical connections between conductors and lands.
Solution Approach 2:
A protruding part is introduced as an intermediary structure that extends from the insulator into the recessed part of the substrate. This protruding part acts as a barrier or shield, blocking foreign matter from reaching the electrical connection region while allowing the electrical connections to function normally.
2Reliability
If complex connection structures are used to prevent foreign matter entry, then reliability improves, but manufacturing complexity increases
Solution Approach 1:
The protruding part serves multiple functions simultaneously: it acts as a barrier against foreign matter, provides structural support for the substrate, and defines the boundary of the connection region. This multi-functionality reduces the need for additional separate components, simplifying the overall structure while maintaining reliability.
Solution Approach 2:
The protruding part is integrated with the insulator as a single component, combining the insulation function with the foreign matter barrier function. This merging of functions reduces the number of separate parts and simplifies the manufacturing process while ensuring reliable electrical connections.
3Ease of manufacture
If the substrate has a flat surface design, then manufacturing is simpler, but foreign matter can easily enter connection spaces
Solution Approach 1:
The substrate surface is segmented into a recessed connection region and a nonconnection region. The recessed part creates a physical barrier that prevents foreign matter from entering the connection space, while the overall substrate manufacturing process remains relatively simple using standard molding techniques.
Data Source
AI summary
There is provided an easily manufacturable motor. The motor comprises a conductor (27), a stator including an insulator, a stator core, and a coil, and a substrate (40) including an outer peripheral portion (41) and a surface surrounded with the outer peripheral portion (41). The insulator includes a protruding part (34) extending in a rotary shaft direction. The outer peripheral portion (41) of the substrate (40) includes a recessed part 44 recessed in a radial direction. The protruding part (34) is present inside the recessed part (44). A land (47) is provided at the surface of the substrate (40). The land (47) faces any one of the insulator, the stator core, and the coil in the rotary shaft direction. The conductor (27) is electrically connected to the land (47) by a conductive member.