DESC:TECHNICAL FIELD
[0001] The present disclosure generally relates to the field of electrical devices. In particular it pertains to mounting of a PCB for interconnection with plurality of connecting pins in a driven device.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] DC motors have many advantages over their AC counterparts. Low power consumption, maximum torque when stationary (high starting torque) that decreases linearly as velocity increases are two of these. However, with AC becoming universal mode of power transmission &supply, and conversion of power from AC to DC requiring a bulky and inefficient transformer, there had been no option but to use AC motors except for certain special applications.
[0004] With developments in electronics during last few decades, it has now become possible to make more efficient and light weight electronic power transformation systems for conversion from AC to DC that can be mounted within the motor. In addition, electronic switching controlled by a microcontroller electronic system (Hall Effect sensor or software is used to recognize the rotor position based on which the stator current can be commutated) that drives stator have replaced the Carbon brushes which were the negative aspect of DC motors. Such motors are commonly known as Electronically Commutated or Electronically Driven DC motors OR Brushless DC motors.
[0005] Typically, the electronic power transformation system, electronic switching control system and Hall Effect sensors, if used, are all incorporated on a PCB that is mounted within the motor. In these motors the connections to stator windings (such as bobbins) are generally made by use of jumpers from one winding to another. In a separate patent application, it has been proposed that these connections be made on the PCB itself. To make such connections the conductive pins are molded with an insulation ring on either side of the stator at suitable places or with an insert molded stator or bobbins with winding connected to these pins.
[0006] Due to high voltage related clearance requirements these pins have to be rather long and tend to bend randomly during handling/ processing etc. Bent pins pose a major problem in assembling the PCB. Since PCB has holes matching the size of pins and has large number of holes, it is very difficult and time consuming to simultaneously align all the pins with holes on PCB and install the PCB.
[0007] There is therefore need in the art for a solution to solve the problem of mismatch between connection pins and corresponding holes on the PCB and provide a method and/or device that can reduce if not eliminate manual effort in aligning set of connection pins with corresponding holes on PCB thus help improve efficiency during assembly of electrical devices such as electronically driven motors.
[0008] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
[0009] In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
[0010] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0011] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0012] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.

OBJECTS OF THE INVENTION
[0013] An object of present disclosure is to overcome problems associated with matching of plurality of connection pins with corresponding holes of PCB of an electrical device such as an electronically commutated DC motor.
[0014] Another object of present disclosure is to make process of assembly of PCB on an electrical device such as an electronically commutated DC motor efficient and less time consuming.
[0015] Another object of present disclosure is to provide a part that when fitted in the electrical device automatically aligns the connection pins with corresponding holes on PCB.
[0016] Another object of present disclosure is to provide a part that does not take much time in fitting and aligning the connection pins with corresponding holes on PCB.
[0017] Another object of present disclosure is to provide a part for aligning the connection pins with corresponding holes on PCB that is cheap and cost effective to use.

SUMMARY
[0018] Aspects of present disclosure relate to electrical devices such as an electronically commutated DC motor (interchangeably referred to as electronically driven motor or brushless DC motor or simply as motor or electric motor hereinafter). In an aspect the present disclosure pertains to assembly of PCB in the device that has plurality of connection pins such as those pertaining to stator windings of the motor for connectivity with electronic control circuit configured on the PCB.
[0019] It is to be appreciated that though various embodiments of the disclosure have been described with reference to electronically driven motor and connection pins pertaining to its stator windings, they are equally applicable to any other electrical device, assembly of which poses similar challenge i.e. aligning of plurality of connection pins with corresponding holes on the PCB.
[0020] In an aspect the present disclosure provides a spacer that when configured in motor helps in aligning connection pins with corresponding holes in the PCB. In another aspect the disclosed spacer is configured with holes in positions that match in pitch and pitch circle diameter (PCD) with the position of the corresponding holes on PCB where the connection pins are to be received for connectivity. In an aspect, holes of the spacer can be of such diameter so as to allow connection pins to pass through them. In another aspect these holes on the spacer can have enlarged diameters on the side from which the pins shall take entry. The enlarged end of the holes helps in receiving even the pins that may be bent or out of alignment from their correct positions.
[0021] In another aspect the enlarged end of the holes are tapered down to final diameter that corresponds to the diameter of holes on the PCB, to guide the bent/misaligned connection pins to a correct position. Thus enlarged end of the holes coupled with tapering down holes facilitate ease of assembly irrespective of bent/misaligned connection pins. In another aspect of the present disclosure, the disclosed spacer can incorporate raised or projected area around each of its holes that can act as resting surface for the PCB. Plurality of resting faces for the PCB can help in proper positioning of the PCB within the motor. In another aspect other face of the disclosed spacer can also incorporate a flat face/surface that can rest against a suitable surface inside the motor thus providing proper alignment and resting face for the spacer and finally to the PCB.
[0022] In another aspect the disclosed spacer can help in maintaining PCB’s position in respect of height, which in turn can maintain tight control on position of Hall IC which is a critical requirement in these motors.
[0023] In yet another aspect of the disclosure, the disclosed spacer can be manufactured from a light weight electrically insulating material that is amenable to mass production at low cost such as plastic of suitable grade. Thus the disclosed spacer can be cost effective solution to overcome the problems associated with assembly of PCBs on electronically commutated DC motors.
[0024] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components

BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
[0026] FIG. 1 and FIG. 1A illustrate a typical arrangement of stator windings and connection pins in an electronically commutated DC motor.
[0027] FIG. 2, FIG. 2A, FIG. 2B and FIG. 2C illustrate sectional view of a typical electronically commutated DC motor depicting misalignment and bending of connection pins typically faced during assembly of the PCB.
[0028] FIG. 3 illustrates an exemplary top view of the spacer in accordance with embodiments of the present disclosure.
[0029] FIG. 4 and FIG. 4A illustrate exemplary sectional views of the spacer in accordance with embodiments of the present disclosure.
[0030] FIG. 5 and FIG. 5A illustrate sectional views of an electronically commutated DC motor configured with the spacer in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION
[0031] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0032] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.
[0033] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0034] The term ‘pitch’ as used hereinafter refers to relative point or position of holes, bolts or pins on a planar surface.
[0035] The term ‘pitch circle diameter’ or ‘PCD’ as used hereinafter refers to the diameter of the circle ( called the pitch circle ) that passes through the centers of a plurality of holes or bolts or pins, such holes, bolts or pins being arranged on the circumference of the pitch circle.
[0036] Embodiments of the present disclosure relate to electronically commutated DC motors (interchangeably referred to as electronically driven or brushless DC motor or simply as motor or electric motor hereinafter). In an aspect the present disclosure pertains to assembly of PCB in the motor that has stator windings (also referred to as bobbins hereinafter) configured with conducting or connection pins for connectivity with electronic control circuit configured on the PCB. In particular a spacer is disclosed that when configured in motor helps in aligning connection pins with corresponding holes in the PCB.
[0037] In an embodiment the disclosed spacer is configured with holes in positions that match in pitch and pitch circle diameter (PCD) with the position of the corresponding holes in PCB where the connection pins are to be received for connectivity. In an aspect, holes of the spacer can be of such diameter so as to allow connection pins to pass through them. In another aspect these holes can have enlarged diameters on the side from which the pins shall take entry. The enlarged ends of the holes can help in receiving the pins that may be bent or out of alignment from their correct positions thus overcoming the difficulty faced in assembling the PCB in the motor, reducing time taken in assembly and bringing overall efficiency and cost benefits.
[0038] In another embodiment, the enlarged ends of the holes can be tapered to a smaller/final diameter that corresponds to the diameter of connection pins. In an aspect the tapered/conical shape of the enlarged ends of holes can help to guide the bent/misaligned pins to their correct positions on the PCB. Thus enlarged ends of the holes of the spacer coupled with tapering down of the enlarged ends of holes can facilitate ease of assembly of PCB in the motor, irrespective of bending / misalignment of pins, automatically guiding the pins in the process of insertion of spacer over pins and aligning them properly with the holes in PCB 108.
[0039] FIG. 1 illustrates an exemplary top view 100 of stator of an electronically commutated motor depicting a typical arrangement of stator windings and connection pins. The top view 100 depicts plurality of poles 102 of stator of the motor, each pole 102 being configured with a stator winding104. Each of the winding104 has two conducting/connection pins 106 connected to two ends of the winding. The connection pins 106 can be configured in such a way as to form a circle 110 when not displaced from their correct positions. Also depicted is a PCB 108 placed above the connection pins 106 and is configured with matching holes with same pitch circle to receive the connection pins 106.Those skilled in the art would appreciate that the hole diameters of the PCB 108 has to correspond to the connection pin diameter due to soldering quality considerations and therefore cannot be increased beyond a specific value just to accommodate bent/misaligned pins 106. As is apparent any displacement of connection pins 106 from their correct position shall result in difficulty in assembly of PCB 108 in the motor. This is especially so because there is large number of connection pins 106 and all of them have to be simultaneously aligned with their respective holes in the PCB 108 for a successful assembly.
[0040] FIG. 1A illustrates an enlarged view of the area ‘A’ of the FIG.1 depicting one of the reasons for misalignment of the connection pins 106. When the winding such as bobbin 104 does not seat snugly against the inside face of the pole 102 leaving a gap 154 as against no gap 152 if it were to seat snugly and properly, the resultant shift in the bobbin 104 shall result in corresponding shift in position of the pins 158-1 and 158-2as shown by arrows ‘X’. The shift ‘X’ in pins 158-1 and 158-2 shall result in their mismatch with corresponding holes 156-1 and 156-2 on the PCB 108. As against the above, pin 160 corresponding to other bobbin that seats snugly with the inside face of the stator pole 102 without any gap 152, aligns with the hole on the PCB 108.
[0041] FIG. 2 illustrates an exemplary sectional view 200 of a typical electronically commutated DC motor depicting misalignment typically faced during assembly of the PCB. Area ‘A’ of the view 200 depicts a pin 106 that is in full alignment with the hole in PCB 108 due to proper seating 202 of bobbin 104 with inner face of stator pole 102. As against this area ‘B’ of the view 200 depicts a connection pin 106 that is misaligned to the hole 156 in PCB 108 due to improper seating with a gap 204 between bobbin 104 and inner face of stator pole 102.
[0042] FIG. 2A illustrates enlarged view of ‘A’ 220 depicting pin 106 in full alignment with the hole in PCB 108. FIG. 2B illustrates enlarged view of ‘B’ 240 depicting pin 106 that is misaligned with the hole in PCB 108.
[0043] FIG. 2C illustrates view 260 depicting another reason for mismatch between connection pin 106 and hole in the PCB 108. As shown, at times connection pins 106 may get bent due to mishandling and may not align with the hole in PCB 108.
[0044] FIG. 3 illustrates an exemplary top view of the spacer 300 in accordance with embodiments of the present disclosure. The spacer 300 can be round in shape with a diameter that is slightly larger than the PCD of holes in PCB 108. It is to be appreciated that the holes 302 can define any other shape other than a circle such as a polygon of regular or irregular size depending on the position of the pins 106 and holes on the PCB 108. The spacer can be made of any suitable material that is non-conducting/electrically insulating, lightweight and easy/cheap to mass produce for example but not limited to a plastic of appropriate composition and grade. It is also to be appreciated that shape and configuration of the spacer 300 depicted in FIG. 3 and as described above is only exemplary meeting the specific requirement of an electronically driven DC motor. Other electric devices shall have their specific configurations and shall therefore need the spacer to be shaped matching the specific requirements.
[0045] FIG. 4 and FIG. 4A illustrate exemplary sectional views 400 and 450 of the spacer 300 in accordance with embodiments of the present disclosure. The spacer 300 can be hollow inside to keep its weight low. In a preferred embodiment, it can incorporate plurality of raised portion402 - one around each hole 302. Top face of the raised part 402 can provide a resting face for PCB 108. The spacer 300 can have a flat bottom face 404 that can help in locating the spacer 300 against a resting face on stator (not shown) of the motor. Enlarged view 450 of the area ‘A’ of the sectional view 400 depicts the sectional details of the hole 302. In an embodiment the holes 302 can have enlarged diameters 452 on the side from which the pins shall take entry. The enlarged ends 452 of the holes 302 help in receiving the pins that may be bent or out of alignment from their correct positions thus overcoming the difficulty faced in assembling the PCB 108 in the motor, reducing time taken in assembly and bring overall efficiency and cost benefits.
[0046] In another embodiment, the enlarged ends 452 of the holes 302 can be tapered down - as shown by ‘B’ on FIG. 4A, to a smaller/final diameter that corresponds to the diameter of pins 106.In an aspect the tapered/conical shape of the enlarged ends 452 of holes 302 can help to guide the bent/misaligned pins 106 to their correct positions on PCB 108. Thus enlarged end 452 of the holes 302 coupled with tapering down of the enlarged ends 452 of holes 302 can facilitate ease of assembly of PCB 108 in the motor, irrespective of bending / misalignment of pins 106, automatically guiding the pins 106 during the process of insertion of spacer 300 over pins 106.FIG. 5 and FIG. 5A illustrate exemplary sectional views 500 and 550 of an electronically commutated DC motor configured with the spacer 300 in accordance with embodiments of the present disclosure. The sectional views 500 depicts spacer 300 resting on the top face of the stator and the PCB 108 placed on the top face of the raised part on the spacer 108 maintaining a gap ‘Y’ between bobbins 104 and PCB 108. Also depicted in view 550 are connection pins 106 passing through the holes in spacer 300 and also holes on the PCB 108. The pins 106 can now be soldered to the PCB 108 and PCB 108’s position, height and location can be maintained by the spacer.
[0047] In another aspect the spacer 300 by precisely controlling the radial orientation, height i.e. ‘Y’ and location of PCB 108 can also allow the position of Hall IC (not shown) that is mounted on PCB 108, to be tightly controlled in relation with stator that is a critical requirement in these motors.
[0048] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE INVENTION
[0049] The present disclosure overcomes problems associated with matching of plurality of connection pins with corresponding holes of PCB of an electrical device such as an electronically commutated DC motor.
[0050] The present disclosure makes process of assembly of PCB on an electrical device such as an electronically commutated DC motor efficient and less time consuming.
[0051] The present disclosure provides a part that when fitted in the electrical device automatically aligns the connection pins with corresponding holes on PCB.
[0052] The present disclosure provides a part that does not take much time in fitting and aligning the connection pins with corresponding holes on PCB.
[0053] The present disclosure provides a part for aligning the connection pins with corresponding holes on PCB that is cheap and cost effective to use.
,CLAIMS:1. An electronically commutated DC motor comprising:
a stator incorporating plurality of connection pins for connectivity between the stator windings and an electronic control circuit configured for commutating current flow to the stator windings;
a PCB configured with the electronic control circuit; and
a spacer placed between the stator and the PCB, wherein the spacer is configured to facilitate aligning of the connection pins with corresponding holes on the PCB, and further configured to maintain the PCB in a desired position relative to the stator.
2. The motor of claim 1, wherein the PCB incorporates first set of holes for entry of the connection pins and subsequent soldering for providing the connectivity between the stator windings and the electronic control circuit configured on the PCB.
3. The motor of claim 2, wherein the spacer comprises a second set of holes matching the first set of holes on the PCB and position of the connection pins; and wherein the second set of holes is configured to allow connection pins of the electric motor to pass through them.
4. The motor of claim 3, wherein the spacer incorporates raised area around each of the second set of the holes, wherein the raised area acts as resting surface for the PCB.
5. The motor of claim 3, wherein the second set of holes have enlarged diameters on side facing the stator windings.
6. The motor of claim 5, wherein the enlarged diameters of the second set of holes is at end of conical/tapered cross section.
7. The motor of claim 1, wherein the spacer incorporates a flat surface and the flat surface rests against a surface of the stator.
8. The motor of claim 1, wherein the PCB also incorporates one or more hall sensors to ascertain rotor position based on which the electronic control circuit commutates the stator current.
9. The motor of claim 1, wherein the desired position of the PCB relative to the stator includes radial orientation and axial distance of the PCB.
10. The motor of claim 1, wherein the spacer is made of an electrically insulating material.