Coil board and coil board for motor

Abstract

Provided is a coil substrate having a high duty factor, the coil substrate (10) according to an embodiment comprising: a flexible substrate (22) having one end (22L) and the other end (22R); and a coil (C) formed on the flexible substrate (22). Furthermore, at least three coils (C) partially overlap.

Description

Technical Field

[0001] The present invention relates to a coil substrate and a coil substrate for a motor. Background Art

[0002] Patent Document 1 discloses a motor coil substrate including a flexible insulating substrate and a coil.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Publication No. 2019-140762 Summary of the Invention

[0006] [Patent Literature Issues]

[0007] FIG5 of Patent Document 1 shows the coil configuration. According to FIG5 of Patent Document 1, Coil C1 and Coil C2 partially overlap. Coil C1 and Coil C3 do not overlap. Therefore, it is considered difficult to increase the coil space factor using the technology of Patent Document 1.

[0008] In the motor coil substrate of Patent Document 1, a flexible insulating substrate is wound. The number of turns of the flexible insulating substrate exceeds one. Therefore, the motor coil substrate of Patent Document 1 is believed to include at least a first turn of a flexible insulating substrate (a first flexible insulating substrate) and a second turn of a flexible insulating substrate (a second flexible insulating substrate) wound outside the first flexible insulating substrate. The first portion of the second flexible insulating substrate extends from the last portion of the first flexible insulating substrate. The second flexible insulating substrate is wound around the first flexible insulating substrate. If the flexible insulating substrate is wound so that the flexible insulating substrate forms a cylindrical shape, the distance between the center of the cylinder and the first portion of the first flexible insulating substrate is believed to be different from the distance between the center of the cylinder and the last portion of the first flexible insulating substrate. In the technology of Patent Document 1, the position of the coil formed on the first portion of the first flexible insulating substrate is believed to be inconsistent with the position of the coil formed on the first portion of the second flexible insulating substrate. When the technology of Patent Document 1 is used to form a motor, it is believed that it is difficult to provide a high-performance motor.

[0009] Means for solving problems

[0010] The coil substrate of the present invention comprises: a flexible substrate including a first flexible substrate having one end and a second flexible substrate extending from the first flexible substrate; and a plurality of coils formed on the flexible substrate. Furthermore, the coils are arranged substantially in a row, and include an mth coil, an (m+1)th coil, an (m+2)th coil, an (m+3)th coil, and an (m+4)th coil. The (m+1)th coil is located below the mth coil, the (m+2)th coil is located below the (m+1)th coil, the (m+3)th coil is located below the (m+2)th coil, and the (m+4)th coil is located below the (m+3)th coil. The mth coil, the (m+1)th coil, and the (m+2)th coil partially overlap, and the mth coil and the (m+4)th coil do not overlap, where m is a natural number.

[0011] [Effects of the embodiment]

[0012] The coil substrate according to an embodiment of the present invention comprises a flexible substrate including a first flexible substrate and a second flexible substrate extending from the first flexible substrate, and a plurality of coils formed on the flexible substrate. Furthermore, the mth coil, the (m+1)th coil, and the (m+2)th coil partially overlap. In some embodiments, at least three coils overlap. This improves the coil's space factor.

[0013] By winding the coil substrate of the embodiment, a coil substrate for a motor can be manufactured. The second flexible substrate is wound around the first flexible substrate. The first flexible substrate forms a first circle, and the second flexible substrate forms a second circle. The coil on the first flexible substrate is an inner coil, and the coil on the second flexible substrate is an outer coil. The number of inner coils (first number) and the number of outer coils (second number) are multiple, and the first number and the second number are the same. The inner coil has an initial inner coil closest to one end of the first flexible substrate and a last inner coil closest to the second flexible substrate. The last inner coil has a second width, and the initial inner coil has a first width. Moreover, the second width is greater than the first width. By adjusting the second width, the length of the first flexible substrate can be adjusted. By adjusting the second width, the position of the coil within the motor coil substrate can be adjusted. According to the embodiment, the position of the inner coil can be made consistent with the position of the outer coil with high precision. A high-performance coil substrate for a motor can be provided. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 (A) is a schematic diagram of a motor according to an embodiment, Figure 1 (B) is a schematic diagram of a motor coil substrate according to an embodiment. Figure 1 (C) is the top view of the wiring. Figure 1(D) is a schematic diagram of the coil, Figure 1 (E) is a cross-sectional view of the coil.

[0015] Figure 2 It is a cross-sectional view of the inner coil.

[0016] Figure 3 It is a schematic diagram showing a cross section of a motor coil substrate according to an embodiment.

[0017] Figure 4 (A) is a top view of the coil substrate of the embodiment. Figure 4 (B) shows the circumference of an imaginary circle and a cross section of a portion of the motor coil substrate. DETAILED DESCRIPTION

[0018] [Implementation Method]

[0019] Prepare Figure 4 The coil substrate 10 shown in FIG. 1 is formed of a flexible substrate 22 having a first surface F and a second surface S opposite to the first surface F, and coils C ( C1 to C9 ) on the flexible substrate 22 . The flexible substrate 22 has one end 22L and the other end 22R. Figure 4 The coil C is shown schematically. By winding the coil substrate 10, Figure 1 The motor coil substrate 20 shown in (B) is shown. For example, the coil substrate 10 is wound into a cylindrical shape. The motor coil substrate 20 is wound around the cavity AH. The coil substrate 10 is wound so that the first surface F faces the cavity AH. For example, the motor coil substrate 20 is in the shape of a cylinder. The number of winding turns N is greater than or equal to 2 and less than or equal to 5. Figure 1 (B) is a schematic diagram.

[0020] like Figure 1 As shown in FIG. 1 (A), the motor 110 is obtained by arranging the magnet 48 in the motor coil substrate 20 . Figure 1 (A) is a schematic diagram. The motor coil substrate 20 is arranged around the magnet 48 via the cavity AH. An example of the motor 110 is a brushless motor. In the embodiment, the magnet 48 rotates, but the motor coil substrate 20 may also rotate.

[0021] Figure 1 (C) shows an example of a coil C. The coil C is formed by a central space SC and a wiring w surrounding the central space SC. The wiring w has an output portion OE and an input portion IE. The wiring w is formed between the output portion OE and the input portion IE. The wiring w forming the coil C is formed in a spiral shape. The central space SC is surrounded by the innermost wiring Iw of the wiring w forming the coil C. The outermost wiring w is the outer wiring Ow. The wiring w forming the coil C is formed around the central space SC.

[0022] form Figure 1 The wiring w of coil C in (C) is depicted using solid lines, dashed lines, and circles. The solid line represents the wiring wf on the first surface F (first-surface wiring). The dashed line represents the wiring ws on the second surface S (second-surface wiring). The circle represents the via conductor V. The via conductor V connects the first-surface wiring wf with the second-surface wiring ws. The via conductor V includes a first via conductor V1 that connects the first-surface wiring wf and the second-surface wiring ws within a single turn, and a second via conductor V2 that connects different turns. One first-surface wiring wf, one first via conductor V1, and one second-surface wiring ws form one turn.

[0023] like Figure 1 As shown in (C), the wiring w includes a plurality of first wirings 51 and a plurality of second wirings 52 that are opposite to each other across a central space SC. In one coil C, the first wiring 51 is close to one end 22L, and the second wiring 52 is close to the other end 22R. The first wirings 51 are formed to be approximately parallel. The second wirings 52 are formed to be approximately parallel. The first wirings 51 and the second wirings 52 are formed to be approximately parallel. When the motor 110 is manufactured using the coil substrate 10 of the embodiment, Figure 1 The angle between the motor's rotational direction MR and the first wiring 51 shown in (B) is approximately 90 degrees. The angle between the direction of current flowing through the first wiring 51 and the motor's rotational direction MR is approximately 90 degrees. The wiring w further includes a third wiring 53 that connects the first wiring 51 and the second wiring 52.

[0024] The outermost first wiring 51 among the plurality of first wirings 51 is an outer first wiring 510w. The innermost wiring among the plurality of first wirings 51 is an inner first wiring 511w. The inner first wiring 511w faces the central space SC.

[0025] The outermost second wiring 52 among the plurality of second wirings 52 is an outer second wiring 52Ow. The innermost second wiring 52 among the plurality of second wirings 52 is an inner second wiring 52Iw. The inner second wiring 52Iw faces the central space SC.

[0026] Figure 1 (E) is a cross-sectional view of coil C. Figure 1 (E) shows the cross-section of the first wiring 51 and the second wiring 52 .

[0027] Figure 1 (D) schematically shows the coil C. Figure 1In (D), the wirings w are grouped together. When the wirings w are grouped together, a wiring group is formed. The first wiring group 51g is formed by grouping the first wirings 51 together. The first wiring group 51g is formed by all the first wirings 51 together. The second wiring group 52g is formed by grouping the second wirings 52 together. The second wiring group 52g is formed by all the second wirings 52 together. Figure 1 In (D), the coil C is depicted using a wiring group. The wiring group on the first surface F is depicted with horizontal lines. The wiring group on the second surface S is depicted with oblique lines. Figure 4 The coil C in (A) is depicted by the wiring group.

[0028] like Figure 4 As shown in (A), the flexible substrate 22 has a short side 20S and a long side 20L. The flexible substrate 22 has one end 22L and another end 22R opposite to the one end 22L. The short side 20S also serves as the one end 22L. Coils C (C1-C9) are arranged along the long side 20L of the flexible substrate 22. The coils C are arranged roughly in a row from one end 22L to the other end 22R of the flexible substrate 22. The coil C closest to the one end 22L is the first coil C1. Following the first coil C1 is the second coil C2. Following the second coil C2 is the third coil C3. Following the third coil C3 is the fourth coil C4. Following the fourth coil C4 is the fifth coil C5. Thus, the (m+1)th coil is located after the mth coil. The (m+2)th coil is located after the (m+1)th coil. The (m+3)th coil is located after the (m+2)th coil. The (m+4)th coil is located next to the (m+3)th coil.

[0029] The first coil C1, the second coil C2, and the third coil C3 partially overlap. The first coil C1 and the fifth coil C5 do not overlap. Thus, the mth coil, the (m+1)th coil, and the (m+2)th coil partially overlap. The mth coil and the (m+4)th coil do not overlap. In the embodiment, the three coils C overlap. Therefore, the coil space factor can be increased.

[0030] The first coil C1, the second coil C2, the third coil C3, and the fourth coil C4 partially overlap. The first coil C1 and the fifth coil C5 do not overlap. Thus, the mth coil, the (m+1)th coil, the (m+2)th coil, and the (m+3)th coil partially overlap. The mth coil and the (m+4)th coil do not overlap. In the embodiment, the four coils C overlap. Therefore, the coil space factor can be increased.

[0031] The mth coil is close to one end 22L, and the (m+1)th coil is close to the other end 22R. m is a natural number.

[0032] The first coil C1 is a U-phase coil. The second coil C2 is a V-phase coil. The third coil C3 is a W-phase coil. The U-phase coil, V-phase coil, and W-phase coil are arranged in the order of U-phase coil, V-phase coil, and W-phase coil. The coil C closest to one end 22L is the U-phase coil. The number of coils C is a multiple of 3. Figure 4 In the example (A), the number of coils is 9.

[0033] The coil substrate 10 is formed from a single flexible substrate 22. The flexible substrate 22 forming the coil substrate 10 is divided into a plurality of sections P. Therefore, the coil substrate 10 is also divided into a plurality of sections P. The coil substrate 10 is formed from a plurality of sections P, with the number of sections P being N. The sections P forming the coil substrate 10 are arranged from one end 22L toward the other end 22R. The first section P1 includes one end 22L of the flexible substrate 22. The second section P2 is adjacent to the first section P1. For example, N is the number of turns of the flexible substrate 22. The Nth section PN includes the other end 22R of the flexible substrate 22.

[0034] exist Figure 4 In the example of (A), the number of parts P is 2. Figure 4 The coil substrate 10 of (A) is formed of a first portion P1 and a second portion P2. The flexible substrate 22 forming the first portion P1 is a first flexible substrate 22-1. The flexible substrate 22 forming the second portion P2 is a second flexible substrate 22-2. The second flexible substrate 22-2 extends from the first flexible substrate 22-1.

[0035] like Figure 4 As shown in (A), the coil C includes a coil C formed in the first flexible substrate 22-1, a coil C formed in the second flexible substrate 22-2, and coils formed in both the first flexible substrate 22-1 and the second flexible substrate 22-2.

[0036] The coil C formed within the first flexible substrate 22-1 is referred to as an inner coil CI. In the case of an inner coil CI, the entire coil C is formed within the first flexible substrate 22-1. The number of inner coils CI (a first number) is plural. Among the inner coils CI, the coil C closest to one end 22L is the initial inner coil CI1. Among the inner coils CI, the coil C closest to the second flexible substrate 22-2 is the final inner coil CIE. The inner coil CI includes an intermediate inner coil CII between the initial inner coil CI1 and the final inner coil CIE. The number of intermediate inner coils CII is one or four.

[0037] exist Figure 4In the example (A), the first number is 3, and the number of middle inner coils C1I is 1. The first inner coil CI1, the middle inner coil C1I, and the last inner coil C1E are formed on the first flexible substrate 22-1. The first coil C1 is the first inner coil CI1. The second coil C2 is the middle inner coil C1I. The third coil C3 is the last inner coil C1E.

[0038] The coil C formed on the second flexible substrate 22-2 is referred to as an outer coil CO. In the case of an outer coil CO, the entire coil C is formed within the second flexible substrate 22-2. The number of outer coils CO (the second number) is plural. The first number is the same as the second number. Among the outer coils CO, the coil C closest to the first flexible substrate 22-1 is the initial outer coil CO1. Among the outer coils CO, the coil C closest to the other end 22R is the final outer coil COE. The outer coils CO include intermediate outer coils COI between the initial outer coil CO1 and the final outer coil COE. The number of intermediate outer coils COI is one or four. The seventh coil C7 is the initial outer coil COI. The eighth coil C8 is the intermediate outer coil COI. The ninth coil C9 is the final outer coil COE.

[0039] exist Figure 4 In the example of (A), the second number is 3, and the number of the middle outer coil COI is 1. The first outer coil CO1, the middle outer coil COI, and the last outer coil COE are formed on the second flexible substrate 22-2.

[0040] Each coil C has Figure 1 (D) and Figure 1 The distance (width) W shown in (E). The first wiring 51 has a first side wall sw1 facing the central space SC and a second side wall sw2 on the side opposite to the first side wall sw1. The second wiring 52 has a third side wall sw3 facing the central space SC and a fourth side wall sw4 on the side opposite to the third side wall sw3. In the wiring w forming a coil C, the distance between the second side wall sw2 of the outer first wiring 51Ow and the fourth side wall sw4 of the outer second wiring 52Ow is the width W. Alternatively, the width W is measured along a straight line perpendicular to the first wiring 51. Alternatively, the width W is measured along the long side 20L of the flexible substrate 22. Alternatively, in Figure 4Two straight lines (a first straight line L1 and a second straight line L2) are prepared on the coil substrate 10 shown in (A). The first straight line L1 is parallel to the second straight line L2. The angle between the first straight line L1 and the rotation direction MR of the motor 110 is approximately 90 degrees. Each coil C is sandwiched between the first straight line L1 and the second straight line L2. The distance between the first straight line L1 and the second straight line L2 that sandwich the coil C is the width W of the coil C. The first inner coil CI1 has a first width w1. The middle inner coil CII has a first width w1. The last inner coil CIE has a second width w2. For example, when the first inner coil CI1 is sandwiched between the first straight line L1 and the second straight line L2, the distance between the first straight line L1 and the second straight line L2 is the first width w1. When the last inner coil CIE is sandwiched between the first straight line L1 and the second straight line L2, the distance between the first straight line L1 and the second straight line L2 is the second width w2. When the middle inner coil CII is sandwiched between the first straight line L1 and the second straight line L2, the distance between the first straight line L1 and the second straight line L2 is the first width w1.

[0041] The central space SP of each coil C has a width. The width of the central space SP is the distance between the first side wall sw1 of the inner first wiring 51Iw and the third side wall sw3 of the inner second wiring 52Iw. Alternatively, the width can be measured by sandwiching the central space SP between a first straight line and a second straight line. The distance between the first and second straight lines is the width of the central space SP.

[0042] Figure 2 The width W of the initial inner coil CI1, the width W of the intermediate inner coil CII, and the width W of the final inner coil CIE are shown. The width of the initial inner coil CI1 (first width w1) is approximately equal to the width of the intermediate inner coil CII (first width w1). The width of the final inner coil CIE (second width w2) is greater than the first width w1.

[0043] Figure 2 (A) shows the cross section of the initial inner coil CI1. Figure 2 (B) shows a cross section of the middle inner coil CII. Figure 2 (C) shows the cross section of the final inner coil CIE. In these figures, cross sections of the first wiring 51 and the second wiring 52 are depicted.

[0044] The first wiring 51 forming the initial inner coil CI1 has a width (the eleventh width) x1. The width x1 of each first wiring 51 in the initial inner coil CI1 is substantially equal.

[0045] A space B1 is formed between adjacent first wirings 51 in the first inner coil CI1. The space B1 has a width b1. The widths (the twenty-first widths) b1 of the spaces B1 in the first inner coil CI1 are substantially equal.

[0046] The second wiring 52 forming the initial inner coil CI1 has a width (the twelfth width) x 2. The width x 2 of each second wiring 52 in the initial inner coil CI1 is substantially equal.

[0047] A space B2 is formed between adjacent second wirings 52 in the first inner coil CI1. The space B2 has a width (the twenty-second width) b2. The widths b2 of the spaces B2 in the first inner coil CI1 are substantially equal.

[0048] The first wiring 51 forming the middle inner coil CII has a width (a thirteenth width) y1. The widths y1 of the first wirings 51 in the middle inner coil CII are substantially equal.

[0049] A space D1 is formed between adjacent first wirings 51 in the middle inner coil CII. The space D1 has a width (the twenty-third width) d1. The widths d1 of the spaces D1 in the middle inner coil CII are substantially equal.

[0050] The second wiring 52 forming the middle inner coil CII has a width (fourteenth width) y2. The widths y2 of the second wirings 52 in the middle inner coil CII are substantially equal.

[0051] A space D2 is formed between adjacent second wirings 52 in the middle inner coil CII. The space D2 has a width (the twenty-fourth width) d2. The widths d2 of the spaces D2 in the middle inner coil CII are substantially equal.

[0052] The first wiring lines 51 forming the final inner coil CIE have a width (fifteenth width) z1. The widths z1 of the first wiring lines 51 in the final inner coil CIE are substantially equal.

[0053] A space Q1 is formed between adjacent first wirings 51 in the last inner coil CIE. The space Q1 has a width (the twenty-fifth width) q1. The widths q1 of the spaces Q1 in the last inner coil CIE are substantially equal.

[0054] The second wiring 52 forming the final inner coil CIE has a width (the sixteenth width) z2. The widths z2 of the second wirings 52 in the final inner coil CIE are substantially equal.

[0055] A space Q2 is formed between adjacent second wirings 52 in the last inner coil CIE. The space Q2 has a width (the twenty-sixth width) q2. The widths q2 of the spaces Q2 in the last inner coil CIE are substantially equal.

[0056] The eleventh width x1, the twelfth width x2, the thirteenth width y1, the fourteenth width y2 and the fifteenth width z1 are substantially equal, and the sixteenth width z2 is greater than the eleventh width x1.

[0057] The twenty-first width b1, the twenty-second width b2, the twenty-third width d1, the twenty-fourth width d2, the twenty-fifth width q1, and the twenty-sixth width q2 are substantially equal.

[0058] A width SP1 of the central space SP of the first inner coil CI1, a width SP2 of the central space SP of the middle inner coil CII, and a width SP3 of the central space SP of the last inner coil CIE are substantially equal.

[0059] Based on these relationships, the width w2 of the final inner coil CIE can be made larger than the width w1 of the initial inner coil CI1. The width w2 of the final inner coil CIE can also be made larger than the width w1 of the intermediate inner coil CII. By adjusting the sixteenth width z2, the width w2 of the final inner coil CIE is adjusted. The width w1 of the initial inner coil CI1 can be made approximately equal to the width w1 of the intermediate inner coil CII.

[0060] The first wiring group 51g has a width. The width of the first wiring group 51g is the distance between the second side wall sw2 of the outer first wiring 51Ow and the first side wall sw1 of the inner first wiring 51Iw. Alternatively, the width of the first wiring group 51g can be measured along a straight line perpendicular to the first wiring 51. Alternatively, the width can be measured by sandwiching the first wiring group 51g between the first straight line L1 and the second straight line L2. The distance between the first straight line L1 and the second straight line L2 is the width of the first wiring group 51g.

[0061] The second wiring group 52g has a width. The width of the second wiring group 52g is the distance between the fourth side wall sw4 of the outer second wiring 520w and the third side wall sw3 of the inner second wiring 521w. Alternatively, the width of the second wiring group 52g can be measured along a straight line perpendicular to the first wiring 51. Alternatively, the width can be measured by sandwiching the second wiring group 52g between the first straight line L1 and the second straight line L2. The distance between the first straight line L1 and the second straight line L2 is the width of the second wiring group 52g.

[0062] like Figure 2 As shown in FIG. 5A , the first wiring group 51g of the first inner coil CI1 has a first wiring group width (the 31st width) w3 . The second wiring group 52g of the first inner coil CI1 has a second wiring group width (the 32nd width) w4 .

[0063] like Figure 2As shown in FIG. 5B , the first wiring group 51g of the middle inner coil CII has a first wiring group width (the 33rd width) w5. The second wiring group 52g of the middle inner coil CII has a second wiring group width (the 34th width) w6.

[0064] like Figure 2 As shown in (C), the first wiring group 51g of the last inner coil C1E has a first wiring group width (the 35th width) w7. The second wiring group 52g of the last inner coil C1E has a second wiring group width (the 36th width) w8.

[0065] The thirty-first width w3, the thirty-second width w4, the thirty-third width w5, the thirty-fourth width w6, and the thirty-fifth width w7 are substantially equal to each other. The thirty-sixth width w8 is greater than the thirty-first width w3.

[0066] A width SP1 of the central space SP of the first inner coil CI1, a width SP2 of the central space SP of the middle inner coil CII, and a width SP3 of the central space SP of the last inner coil CIE are substantially equal.

[0067] Based on these relationships, the width w2 of the final inner coil CIE can be made larger than the width w1 of the initial inner coil CI1. By adjusting the thirty-sixth width w8, the width w2 of the final inner coil CIE is adjusted. The width w2 of the final inner coil CIE can be made larger than the width w1 of the intermediate inner coil CII. The width w1 of the initial inner coil CI1 can be made substantially equal to the width w1 of the intermediate inner coil CII.

[0068] The motor coil substrate 20 of the embodiment is obtained by winding the coil substrate 10. The coil substrate 10 is wound so that each portion P forms approximately one turn. Figure 1 (B) illustrates an example of a method for winding the coil substrate 10. Figure 4 When the coil substrate 10 of (A) is wound, the first portion P1 forms approximately one circle. The second portion P2 connected to the first portion P1 forms approximately one circle. Figure 1 As shown in (B), the first portion P1 is wound inside. The first portion P1 forms the first loop. The flexible substrate 22 forming the first portion P1 is the first flexible substrate 22-1. The second portion P2 is wound outside the first portion P1. The second portion P2 forms the second loop. The flexible substrate 22 forming the second portion P2 is the second flexible substrate 22-2.

[0069] Figure 3 (B) schematically shows a cross section of the motor coil substrate 20. Figure 3In (B), the motor coil substrate 20 is cut with a surface parallel to the rotation direction MR of the motor 110. Figure 3 As shown in (B), the motor coil substrate 20 can be divided into equal areas. The first wiring group 51g or the second wiring group 52g is configured in each area. Alternatively, the first wiring group 51g and the second wiring group 52g are configured in each area. In this case, the first wiring group 51g and the second wiring group 52g of the same phase are configured in one area. For example, the first wiring group 51g forming a U-phase coil and the second wiring group 52g forming a U-phase coil are configured. When a plurality of wiring groups are configured in one area, each wiring group configured in one area forms a different coil C. The first wiring group 51g and the second wiring group 52g in one coil C are not configured in one area. The first wiring group 51g and the second wiring group 52g in one coil C are not configured in the same area.

[0070] exist Figure 3 In (B), the motor coil substrate 20 is divided into six regions. The central angle of each region is approximately 60 degrees. The region between 0 and 60 degrees is the first region E1. The region between 60 and 120 degrees is the second region E2. Next to the second region E2 is the third region E3. Next to the third region E3 is the fourth region E4. Next to the fourth region E4 is the fifth region E5. Next to the fifth region E5 is the sixth region E6.

[0071] In the first area E1, the first wiring group 51g of the first coil C1, the second wiring group 52g of the fourth coil C4, and the first wiring group 51g of the seventh coil C7 are arranged. In the second area E2, the first wiring group 51g of the second coil C2, the second wiring group 52g of the fifth coil C5, and the first wiring group 51g of the eighth coil C8 are arranged. In the third area E3, the first wiring group 51g of the third coil C3, the second wiring group 52g of the sixth coil C6, and the first wiring group 51g of the ninth coil C9 are arranged. In the fourth area E4, the second wiring group 52g of the first coil C1, the first wiring group 51g of the fourth coil C4, and the second wiring group 52g of the seventh coil C7 are arranged. In the fifth area E5, the second wiring group 52g of the second coil C2, the first wiring group 51g of the fifth coil C5, and the second wiring group 52g of the eighth coil C8 are arranged. In the sixth region E6, the second wiring group 52g of the third coil C3, the first wiring group 51g of the sixth coil C6, and the second wiring group 52g of the ninth coil C9 are arranged.

[0072] Prepare a substrate having a first perimeter and a second perimeter, and a circle r having a radius R. A coil is formed on the first perimeter substrate. A coil is formed on the second perimeter substrate. The length of the first perimeter substrate and the length of the second perimeter substrate are 2πR. The first perimeter substrate extends from its starting point to its ending point. The second perimeter substrate extends from its starting point to its ending point. The ending point of the first perimeter substrate coincides with the starting point of the second perimeter substrate. The second perimeter substrate is wound around the first perimeter substrate. At this time, the first perimeter substrate is wound so that it lies on the circumference of circle r. Then, the second perimeter substrate is wound around the first perimeter substrate. Therefore, the second perimeter substrate is not located on the circumference of circle r. The second perimeter substrate is located outside the circumference of circle r. Therefore, the starting point of the second perimeter substrate is not directly above the starting point of the first perimeter substrate. Therefore, it is difficult to align the positions of the coils on the first perimeter substrate with those on the second perimeter substrate.

[0073] According to the coil substrate 10 of the embodiment, the width of the final inner coil CIE (second width w2) is greater than the width of the initial inner coil CI1 (first width w1). This allows the length of the first flexible substrate 22-1 to be adjusted. Therefore, as in Patent Document 1, even when the second flexible substrate 22-2 is wound around the first flexible substrate 22-1, the position of the initial inner coil CI1 can be precisely aligned with the position of the initial outer coil CO1. The position of the intermediate inner coil CII can be precisely aligned with the position of the intermediate outer coil COI. The position of the final inner coil CIE can be precisely aligned with the position of the final outer coil COE. A motor coil substrate 20 with a high space factor can be obtained.

[0074] The motor coil substrate 20 of the embodiment is cut by a surface including the rotation direction MR of the motor. For example, the motor coil substrate 20 is a cylinder. An example of the shape of the cross section obtained by cutting is as follows: Figure 3 As shown in (A). Figure 3 The shape shown in (A) is roughly a circle.

[0075] exist Figure 3 (A) of FIG. 1 depicts an imaginary circle G. The imaginary circle G has a radius r and a circumference G1. Figure 4 As shown in (B), the upper surface of the wiring wf on the first surface of the first flexible substrate 22-1 is located on the circumference G1. The coil substrate forming the motor coil substrate 20 has a thickness t. Figure 2 As shown in (A), the thickness t is the sum of the thickness of the first flexible substrate 22-1, the thickness of the wiring wf on the first surface of the first flexible substrate 22-1, and the thickness of the wiring ws on the second surface of the first flexible substrate 22-1. Figure 3(A) shows the intersection PO of the extension line of the one end 22L and the circumference G1. Figure 3 (A) shows the intersection point P2 of the extension line of the one end 22L and the extension line of the upper surface of the second surface wiring ws on the first flexible substrate 22-1. Figure 3 (A) shows a straight line CL passing through the intersection P2 and connecting to the imaginary circle G. Figure 3 As shown in (A), the straight line CL touches the imaginary circle G at point P. Figure 3 (A) shows the center BT of the imaginary circle G. Figure 3 , an angle θ between a straight line 1 passing through the intersection point P0 and the center BT and a straight line 2 passing through the point P and the center BT is shown.

[0076] The difference δ between the second width w2 and the first width w1 satisfies Relational Formula 1 including the radius r, the thickness t, and the angle θ. The angle θ satisfies Relational Formula 2.

[0077] Relationship 1: δ = (r + t) sinθ - 2πrθ / 360

[0078] Relationship 2: θ = cos -1 (r / (r+t))

[0079] If the difference δ between the second width w2 and the first width w1 satisfies Relational Expression 1, the position of the inner coil CI and the position of the outer coil CO can be aligned with high precision.

[0080] The width w3 of the first wiring group of the initial inner coil C11 is equal to the width w7 of the first wiring group of the final inner coil C1e. Furthermore, the width w8 of the second wiring group of the final inner coil C1e is greater than the width w4 of the second wiring group of the initial inner coil CI1. In this case, the difference δ between the width w8 of the second wiring group of the final inner coil C1e and the width w4 of the second wiring group of the initial inner coil CI1 satisfies Equation 1.

[0081] An insulating film can be formed on the first surface F of the flexible substrate 22 and the wiring wf on the first surface. An insulating film can also be formed on the second surface S of the flexible substrate 22 and the wiring ws on the second surface. When the insulating film is formed, the coil substrate 10 includes the insulating film. When the coil substrate 10 includes the insulating film, the thickness t includes the thickness of the insulating film.

[0082] Regarding the width W of the coil C, the inner coil CI and the outer coil CO have the same relationship. The width of the initial outer coil CO1 is approximately equal to the width of the middle outer coil COI. The width of the final outer coil COE is larger than the width of the initial outer coil CO1. The width of the final outer coil COE is adjusted according to the width of the second wiring 52 of the final outer coil COE. In the final outer coil COE, the width of the second wiring 52 is larger than the width of the first wiring 51. The width of the final outer coil COE is adjusted according to the width of the second wiring group 52g of the final outer coil COE. In the outer coil COE, the width of the second wiring group 52g is larger than the width of the first wiring group 51g. In this way, the inner coil CI and the outer coil CE adjust the width W of the coil C in the same way.

[0083] Label Description

[0084] 10: Coil substrate; 20: Motor coil substrate; 22: Flexible substrate; 22-1: First flexible substrate; 22-2: Second flexible substrate; 48: Magnet; C: Coil.

Claims

1. A coil substrate, comprising: a flexible substrate comprising a first flexible substrate having one end and a second flexible substrate extending from the first flexible substrate; and a plurality of coils formed on the flexible substrate, in, The coils are arranged roughly in a row, The coils include an mth coil, an (m+1)th coil, an (m+2)th coil, an (m+3)th coil, and an (m+4)th coil. The (m+1)th coil is located next to the mth coil, The (m+2)th coil is located next to the (m+1)th coil, The (m+3)th coil is located next to the (m+2)th coil, The (m+4)th coil is located next to the (m+3)th coil, The mth coil, the (m+1)th coil, and the (m+2)th coil partially overlap, The mth coil does not overlap with the (m+4)th coil, m is a natural number.

2. The coil substrate according to claim 1, wherein: The mth coil, the (m+1)th coil, the (m+2)th coil, and the (m+3)th coil partially overlap.

3. A coil substrate for a motor, which is manufactured by winding the coil substrate of claim 1, wherein: The second flexible substrate is rolled around the first flexible substrate, The first flexible substrate forms a first circle, The second flexible substrate forms a second periphery, The coil on the first flexible substrate is an inner coil, The coil on the second flexible substrate is an outer coil, The number of the inner coils (first number) and the number of the outer coils (second number) are multiple, the first quantity is the same as the second quantity, The inner coil has an initial inner coil closest to the one end and a final inner coil closest to the second flexible substrate, The coils each have a width, The width of the last inner coil is a second width, The width of the initial inner coil is a first width, The second width is greater than the first width.

4. The motor coil substrate according to claim 3, wherein: The flexible substrate has a short side and a long side, The coils are arranged along the long side, The width is measured along the long side.

5. The motor coil substrate according to claim 3, wherein: When the motor coil substrate is arranged around the magnet, a motor is formed by the magnet and the motor coil substrate. Prepare two straight lines (a first straight line and a second straight line) perpendicular to the rotation direction of the motor, When the last inner coil is sandwiched by the first straight line and the second straight line, the distance between the first straight line and the second straight line is the second width, When the initial inner coil is sandwiched between the first straight line and the second straight line, the distance between the first straight line and the second straight line is the first width.

6. The motor coil substrate according to claim 3, wherein: The inner coil includes an intermediate inner coil between the initial inner coil and the final inner coil, The width of the middle inner coil is substantially equal to the first width.

7. The motor coil substrate according to claim 3, wherein: The coils are respectively formed of a central space and wiring formed around the central space, The coil has a plurality of turns. The wiring includes a plurality of first wirings and a plurality of second wirings, The first wiring and the second wiring face each other across the central space, The first wirings are substantially parallel to each other, The second wirings are substantially parallel to each other, The first wiring and the second wiring are substantially parallel, A first wiring group is formed by all of the first wirings, A second wiring group is formed by all the second wirings, The first wiring group has a width of the first wiring group, The second wiring group has a width of the second wiring group, In the initial inner coil, the width of the first wiring group is substantially equal to the width of the second wiring group. In the last inner coil, a width of the first wiring group is different from a width of the second wiring group.

8. The motor coil substrate according to claim 3, wherein: The number of winding turns N is 2 or more and 5 or less.

9. The motor coil substrate according to claim 3, wherein: The coils are three phases, namely, a U-phase coil, a V-phase coil, and a W-phase coil.

10. The motor coil substrate according to claim 7, wherein: In the last inner coil, the width of the second wiring group is greater than that of the first wiring group.

11. The motor coil substrate according to claim 7, wherein: The inner coil includes an intermediate inner coil between the initial inner coil and the final inner coil, In the middle inner coil, the width of the first wiring group is substantially equal to the width of the second wiring group.

12. The motor coil substrate according to claim 7, wherein: The inner coil is completely disposed within the first flexible substrate, The outer coil is completely disposed within the second flexible substrate.

13. The motor coil substrate according to claim 7, wherein: When the motor coil substrate is arranged around the magnet, a motor is formed by the magnet and the motor coil substrate. An angle between a rotation direction of the motor and the first wiring is approximately 90 degrees.

14. The motor coil substrate according to claim 13, wherein: The flexible substrate has a first surface and a second surface opposite to the first surface. The wiring forming the coil includes a first-surface wiring formed on the first surface and a second-surface wiring formed on the second surface, When the coil substrate is wound, the first surface faces the magnet. preparing a cross section obtained by cutting the motor coil substrate along a plane parallel to the rotation direction of the motor and an imaginary circle, and arranging the imaginary circle and the motor coil substrate in such a manner that the circumference of the imaginary circle and the upper surface of the wiring formed on the first surface of the first flexible substrate almost overlap, The difference (δ) between the second width and the first width satisfies the following relational expression 1, Relationship 1: δ = (r + t) sinθ - 2πrθ / 360 Relation 2: θ = cos -1 (r / (r+t)) r in the relational expression 1 is the radius of the imaginary circle, t in the relational expression 1 is the sum of the thickness of the flexible substrate, the thickness of the wiring on the first surface, and the thickness of the wiring on the second surface, and θ in the relational expression 1 is obtained according to the relational expression 2.

15. The motor coil substrate according to claim 14, wherein: The motor coil substrate further includes an insulating film formed on the first flexible substrate and the inner coil. The thickness t also includes the thickness of the insulating film.

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