PCB 3D Protective Coating for Precise Power Tool Encapsulation
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Solution Overview
Problem
The manual hand brushing process with G6 silicone for protecting the surface of printed circuit boards (PCBs) 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
Utilizing 3D printing technologies to apply a 3D printed protective layer on PCBs, which is sprayed layer by layer, replacing the manual glue brushing process and ensuring accurate application of protective material only where needed, thereby improving efficiency and reducing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual hand brushing process with G6 silicone is used to protect PCB surface, then protective coating is applied, but the process is inefficient and causes material waste
Solution Approach 1:
The patent replaces the manual mechanical brushing process with an automated spray coating system. The spray device applies protective coating through aerosol or liquid spray, eliminating manual labor and significantly improving production efficiency while reducing material waste through precise application control.
Solution Approach 2:
The spray coating system is designed to automatically apply the protective layer without manual intervention. The system can autonomously control spray parameters, movement, and coating thickness, enabling continuous production and eliminating the need for hand brushing operations.
2Reliability
If manual hand brushing process is used, then protective coating is applied, but lots of glue materials are wasted
Solution Approach 1:
The automated spray system replaces manual brushing, enabling precise control of coating application. The spray mechanism delivers exact amounts of protective material only where needed, minimizing overflow and waste compared to manual brushing which inherently uses excess material.
Solution Approach 2:
The spray coating system applies protective material locally and selectively to specific PCB areas requiring protection. By controlling spray direction, distance, and duration, the system ensures coating is applied only where necessary, reducing overall material consumption and waste.
3Reliability
If manual hand brushing process is used, then protective coating is applied, but excess glue removal is needed complicating the process
Solution Approach 1:
The automated spray system replaces manual brushing with a controlled deposition process that applies coating only to required areas. By precisely controlling spray parameters and device movement, the system eliminates the need for subsequent glue removal steps, simplifying the overall process.
Solution Approach 2:
The spray coating system performs preliminary precise application of protective material before any potential issues arise. By controlling the deposition process in advance with accurate positioning and dosage control, the system prevents excess material application that would require removal, thereby simplifying the process.
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
The 3D printed protective layer provides efficient and precise protection, reducing material waste and simplifying the manufacturing process while ensuring effective encapsulation and protection of PCBs in power tools, power devices, and battery packs.
Implementation Method 1
The 3D printed protective layer is formed by spraying a PCB of the at least one PCB multiple times.
Data Source
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.