PCB 3D Protective Coating for Cleaner Power Tool Assembly
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Solution Overview
Problem
The manual hand brushing process for PCB surface protection in power tools, power devices, and battery packs is inefficient, leading to material waste and complicating the process due to excess glue removal.
Innovation Solution
Implementing 3D printed protective layers on PCBs using automated 3D printing technologies to accurately coat and stack protective layers, replacing manual glue brushing and reducing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual hand brushing process is used for PCB surface protection, then the process can be implemented with simple equipment, but the production efficiency is low and material waste is high
Solution Approach 1:
The patent replaces the manual mechanical brushing process with an automated 3D printing system that deposits protective material layer by layer. The 3D printer uses a digital model to precisely control material deposition, eliminating the inefficiencies of manual brushing while reducing material waste through precise extrusion only where needed.
Solution Approach 2:
The patent changes the state of protective material application from a liquid brush-coating process to a controlled extrusion process. The protective material is extruded in precise amounts and positions, with the ability to vary extrusion parameters (amount, position, layer thickness) to match the exact protection needs of different PCB regions.
2Ease of manufacture
If manual hand brushing process is used for PCB surface protection, then the equipment complexity is low, but the production process becomes complicated due to excess glue removal
Solution Approach 1:
The patent replaces manual brushing with automated 3D printing, which uses software control to precisely guide the extrusion head. This automation eliminates the need for manual skill while simplifying the overall process by removing the glue removal step entirely, as the 3D printer only deposits material where needed.
Solution Approach 2:
The patent uses a pre-designed 3D model that defines exactly where protective material should be applied. This preliminary digital planning ensures that material is deposited only in required areas from the start, preventing excess material application and eliminating the need for subsequent removal operations.
3Productivity
If 3D printed protective layer is used for PCB surface protection, then the production efficiency is improved and material waste is reduced, but the device complexity increases
Solution Approach 1:
The patent employs a 3D printing system that, while more complex than manual brushing, provides automated precise material deposition. The complexity is justified by the significant gains in production efficiency and material savings, as the system can operate continuously with high precision without manual intervention.
Solution Approach 2:
The patent utilizes a 3D printing system capable of varying extrusion parameters (flow rate, temperature, layer thickness, deposition speed) to optimize protection quality. This parameter control allows the system to adapt to different PCB designs and protection requirements, maintaining high efficiency across various production scenarios.
Data Source
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AI summary
A power tool includes an electric motor including a drive shaft rotating about a drive axis; an output portion driven by the electric motor to output power; a housing for accommodating the electric motor; and at least one print circuit board (PCB) electrically connected to the electric motor, where at least part of the at least one PCB is covered with a three-dimensional (3D) printed protective layer. In this manner, the automated device is used to accurately coat regions to be protected on the PCB, and 3D printed protective layers may be stacked layer by layer, thereby improving the protection efficiency and reducing material waste.