Power Module PCB Terminals for Compact Motor Wire Routing
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Solution Overview
Problem
Conventional electronic power modules for brushless DC motors in cordless power tools face challenges in efficiently managing wire connections, particularly in small internal housing volumes, where tight wire bend radii can lead to breakage and increased volume requirements.
Innovation Solution
The electronic power module features a module housing with embedded power terminals and a printed circuit board (PCB) configuration that allows for compact wire routing, reducing the need for tight bends and minimizing volume, with power switches capable of delivering at least 600 watts of power within a smaller peripheral envelope.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional wire routing methods are used in small internal housing volumes, then wire connections can be made to the circuit board, but tight bend radii cause wire breakage and increased volume requirements
Solution Approach 1:
The patent transitions wire connections from a planar routing approach to a three-dimensional vertical approach. Power terminals extend perpendicularly from the circuit board, allowing wires to connect in the Z-dimension rather than requiring tight horizontal bends. This dimensional change eliminates the need for sharp wire bends while reducing the overall module footprint, directly resolving the contradiction between compact volume and wire connection reliability.
2Power
If power switches are mounted on a circuit board with perpendicular wire orientations, then power delivery is achieved, but wire breakage risk increases due to tight bend radii
Solution Approach 1:
The patent introduces power terminals as intermediary components that extend perpendicularly from the circuit board. These terminals serve as mediators between the planar circuit board and the wire connections, allowing power delivery while eliminating tight wire bends. The perpendicular terminal structure acts as a transition element that maintains electrical connectivity without requiring fragile sharp-angle wire routing.
3Area of stationary object
If conventional wire routing is used in compact designs, then space is utilized, but wire breakage from tight bends increases
Solution Approach 1:
The patent employs vertical power terminals that extend perpendicular to the circuit board plane, utilizing the Z-dimension to reduce the X-Y footprint area. This three-dimensional approach allows wire connections to be made without tight horizontal bends, simultaneously achieving compact footprint and high wire connection reliability.
Data Source
AI summary
An electronic module for controlling a motor includes a module housing including a bottom surface, walls, and an open face, a printed circuit board (PCB) arranged along a plane within the module housing; a plurality of power terminals; and a plurality of power switches mounted on the PCB to switchably connect a supply of electric power from a power source to the plurality of power terminals. The plurality of power terminals includes first portions projecting outside the module housing through one of the walls along a direction substantially parallel to the plane for coupling to a plurality of wires couplable to the motor, and second portions extending substantially perpendicularly to the plane and electrically contacting the PCB.