Electrical generator or motor structure – Printed-circuit motors and components
Reexamination Certificate
1999-12-21
2001-02-20
Enad, Elvin (Department: 2834)
Electrical generator or motor structure
Printed-circuit motors and components
C310S049540, C310S06700R, C310S06800R, C310S071000
Reexamination Certificate
active
06191506
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates generally to dynamoelectric machines and more particularly to an electronically commutated electric motor having a printed circuit board assembly with position sensing devices and other components for controlling the motor and a method of manufacturing a printed circuit board assembly.
Dynamoelectric machines, in the form of electric motors, have numerous applications, such as for washing machines, compressors, and fans, to name only a few. An important part of the utility of the motor is that it can be manufactured inexpensively and yet provide a reliable, long lasting, quiet, low maintenance motor for an appliance or other machine. Thus, there is a need for a motor which can be easily and rapidly assembled without sacrificing quality and reliability. One source of delay and cost in the manufacturing process is the electrical connections that must be made in the motor. Electronically commutated motors have sensors, such as Hall devices, for detecting the position of the rotor. The sensors are electrically connected to one or more circuit boards which mount control and power components for energizing the windings. The components are mounted on the side of the circuit board facing away from the rotor. However, in some instances components may also be mounted on the side of the circuit board facing toward the rotor. The sensors must be positioned near the magnets of the rotor and thus cannot be mounted on the component side of the circuit boards. Typically, the control and power components are mounted on the circuit board, and then the components are soldered to the boards. In a second manufacturing step, the sensors are mechanically attached on the side opposite and then soldered to the circuit boards.
SUMMARY OF THE INVENTION
Thus, there is a need for a circuit board assembly that is more easily manufactured.
Generally, a dynamoelectric machine of the present invention has a stator having a stator core and winding on the stator core. A rotor including a rotor core is received in a stator bore of the stator core. A permanent magnet is mounted on the rotor core periphery and a rotor shaft is mounted on the rotor core. Bearing means are provided for supporting the rotor shaft for rotation relative to the stator. A first circuit board having electrical components thereon is used in operating the dynamoelectric machine, and a second circuit board having an electrical component in the form of a sensing device thereon is used in determining the position of the rotor. The first circuit board is constructed for mounting the second circuit board thereon so that the second circuit board projects axially inwardly from the first circuit board and the sensing device is disposed in an axial position overlapping the axial position of the permanent magnet.
In another aspect of the present invention, a circuit board assembly generally has a unitary circuit board blank having a first circuit board and a second circuit board formed therein. Printed wiring is disposed on a first side of the first and second circuit boards and electrical components are disposed on a second side of the first and second circuit boards. The electrical components are connected to the printed wiring on the first side of the first and second printed circuit boards, and wiring is connected to the printed wiring on the first circuit board and extends from the first circuit board to the second circuit board on the second side of the first and second circuit boards. The second circuit board is attached by a frangible portion of the circuit board blank to the first circuit board whereby the second circuit board may be selectively removed from the first circuit board while maintaining electrical connection through the wiring.
In another aspect of the present invention, a method of manufacturing a circuit board assembly generally comprises the steps of forming first and second circuit boards from a unitary circuit board blank interconnected by a frangible portion of the circuit board blank. The circuit board blank has printed wiring on a first side thereof, but could also have printed wiring on a second side opposite the first side. Electrical components are mounted on a second side of the unitary circuit board blank on the first circuit board and the second circuit board. The electrical components have leads extending through the first and second circuit boards to the first side thereof. The electrical components are wave soldered to the printed wiring on the first side of the first and second circuit boards.
Other objects and features of the present invention will be in part apparent and in part pointed out hereinafter.
REFERENCES:
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patent: 4992688 (1991-02-01), Cap et al.
patent: 4998865 (1991-03-01), Nakanishi et al.
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patent: 5754411 (1998-05-01), Woychik
patent: 5796592 (1998-08-01), Tanaka
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patent: 5825628 (1998-10-01), Garbelli et al.
patent: 5831358 (1998-11-01), Bobay
patent: 5877574 (1999-03-01), Molnar
GE SME44 Motor Assembly, admitted prior art.
Enad Elvin
General Electric Company
Senniger Powers Leavitt & Roedel
Wasserbauer Damian
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