PCB Crimp Splice for Space-Saving Stator Winding Contacts
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Solution Overview
Problem
Existing methods for electrically contacting stator windings to a printed circuit board are often complex, space-consuming, and difficult to access, especially at higher power levels.
Innovation Solution
A crimp connection using U-shaped splice elements on the printed circuit board allows for easy and space-efficient electrical contact between the stator windings and the printed circuit board, with winding wire end sections inserted parallel to the board surface and compressed to form a permanent connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation displacement contacts are used to contact stator windings to the printed circuit board, then electrical contact is achieved, but the connection becomes difficult to access and complex
Solution Approach 1:
Instead of inserting the contact element axially through the stator winding end as in conventional insulation displacement contacts, the patent inverts the approach by placing the splice element on the printed circuit board and inserting the winding wire ends horizontally into the splice element. This inversion makes the connection area easily accessible from the side of the printed circuit board, eliminating the accessibility problems of conventional methods.
2Reliability
If conventional connection methods are used for stator windings, then electrical contact is established, but the solution becomes space-consuming and complex
Solution Approach 1:
The patent divides the connection system into distinct functional segments: the printed circuit board with its splice elements, and the stator with its winding wires. The splice elements are U-shaped conductive components that are soldered or conductively connected to the printed circuit board, creating a modular connection structure that is simpler and more space-efficient than conventional insulation displacement contacts.
3Ease of manufacture
If splice elements are used for crimp connection, then ease of manufacture and space efficiency improve, but electrical contact quality must be maintained
Solution Approach 1:
The splice elements have a U-shaped cross-section with curved surfaces that wrap around the winding wire ends. This curvature allows the crimping tool to apply compressive force evenly around the wire, creating a reliable electrical contact and mechanical connection. The curved geometry of the splice element is essential for achieving both ease of manufacture and high electrical contact quality.
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 method provides a cost-effective, simple, and space-saving solution for stator-to-printed circuit board connections, improving accessibility and process reliability while maintaining high electrical contact quality.
Implementation Method 1
compressing the splice elements to electrically contact the winding wire end sections with the printed circuit board
Data Source
AI summary
A pump includes an electric motor with a rotor rotatably supported about an axis of rotation and circumferentially surrounding a stator. The stator includes a stator core and coils wound on the stator core. The windings are defined by a winding wire including winding wire end sections that are electrically contacted with a printed circuit board by a crimp connection.