Suspended Capacitor Assembly for Compact Motor Control Modules
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Solution Overview
Problem
The existing motor control modules for vehicle brake systems face challenges in efficient assembly and circuit design due to the occupation of space by capacitor assemblies, leading to increased complexity and potential damage during assembly, as well as limitations in mounting other electronic elements.
Innovation Solution
A motor control module design featuring a capacitor assembly with an electrically conductive connecting element suspended relative to the circuit board, allowing a gap between the capacitor assembly and the circuit board, and utilizing a capacitor holder to position capacitors, which enhances assembly efficiency, reduces heat transfer, and allows for more versatile circuit designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If capacitors are welded to the circuit board through connection holes, then electrical connection is achieved, but space on the circuit board is occupied and assembly complexity increases
Solution Approach 1:
The patent introduces an electrically conductive connecting element as an intermediary component between the capacitors and the circuit board. This connecting element has a first end connected to the capacitors and a second end connected to the circuit board, thereby mediating the electrical connection. This approach eliminates the need for welding capacitors directly to the circuit board, reducing assembly complexity while maintaining reliable electrical connection.
2Reliability
If capacitors are mounted directly on the circuit board, then electrical connection is established, but space for other electronic elements is reduced
Solution Approach 1:
The patent transitions from a two-dimensional mounting approach (welding capacitors directly onto the circuit board surface) to a three-dimensional arrangement by introducing a suspended connecting element. The capacitors are positioned above the circuit board and connected via the conductive element, effectively utilizing the vertical dimension. This dimensional change frees up circuit board area for other electronic elements while maintaining electrical connection.
3Area of stationary object
If capacitors are closely positioned to the circuit board, then space is saved, but heat transfer to the circuit board increases
Solution Approach 1:
The electrically conductive connecting element serves as a thermal intermediary between the capacitors and the circuit board. By positioning the capacitors above the circuit board and connecting them through this intermediate element, thermal contact area is reduced compared to direct mounting. This mediates heat transfer, preventing excessive heat from being conducted directly to the circuit board while still maintaining electrical connection and saving space.
Data Source
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AI summary
The present disclosure discloses a motor control module (120), an actuator, and an electromechanical brake apparatus, which relates to the technical field of mechanical braking. The present disclosure solves issues such as insufficient space and large size caused by directly connecting a circuit board and capacitors in the existing motor control modules. The motor control module (120) according to the present disclosure comprises a circuit board (100) and capacitor assembly (300) including a plurality of capacitors (310) and an electrically conductive connecting element (1000) for electrically connecting the plurality of capacitors (310), the electrically conductive connecting element (1000) being electrically connected to the circuit board (100) and being disposed in a suspended state relative to the circuit board (100), such that a gap (130) is maintained between the capacitor assembly (300) and the circuit board (100). A region that is originally occupied by the capacitor assembly (300) on the circuit board (100) may be saved for mounting other electronic elements, such that mounting of the other electronic elements will not be restricted by the capacitor assembly (300). In this way, a smaller-sized circuit board may be used for a same number of electronic elements.