Coil substrate for motor and motor

Abstract

The invention provides a coil substrate for a motor and a motor formed by using the coil substrate for the motor, wherein the coil substrate for the motor can obtain a high-torque and high-performance motor. A coil substrate for a motor according to an embodiment includes: a flexible substrate having a first surface and a second surface opposite to the first surface; and a plurality of coils formed by wiring provided on the first surface and the second surface, the coil substrate for the motor being formed in a cylindrical shape by being wound in a circumferential direction with a first end in a longitudinal direction of the flexible substrate as a starting point and with an axis extending in a vertical direction perpendicular to the longitudinal direction as a center. The space factor of the coil in the cross section of the coil substrate for the motor is more than 50% and less than 99%.

Description

Technical Field

[0001] The technology disclosed in this specification relates to a motor coil substrate and a motor formed using the motor coil substrate. Background Art

[0002] Patent document 1 discloses a coil substrate having a flexible substrate and spiral coils formed on both surfaces of the flexible substrate. The motor coil substrate is formed by winding the coil substrate into a cylindrical shape. The formed motor coil substrate is arranged inside a cylindrical yoke, and a rotating shaft and a magnet are arranged inside the motor coil substrate, thereby forming a motor.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Publication No. 2022-65910 Summary of the invention

[0006] [Problem of Patent Document 1]

[0007] Among motor performances, there is a demand for improved torque, and further, there is a demand for improved torque in small motors.

[0008] Means for solving problems

[0009] The motor coil substrate of the present invention comprises: a flexible substrate having a first surface and a second surface opposite to the first surface; and a plurality of coils formed by wiring arranged on the first surface and the second surface, the motor coil substrate being formed into a cylindrical shape by winding in a circumferential direction around an axis extending in a vertical direction perpendicular to the longitudinal direction starting from a first end in the longitudinal direction of the flexible substrate. The space factor of the coil in a cross section of the motor coil substrate is 50% or more and 99% or less.

[0010] In the motor coil substrate of the embodiment of the present invention, the space factor of the coil in the cross section of the motor coil substrate is greater than 50% and less than 99%. A high space factor is ensured. Therefore, when a motor is formed using the motor coil substrate of the embodiment of the present invention, a higher torque can be obtained. A high-performance motor can be obtained. Moreover, the torque can be increased in a small motor, and a high-performance motor can be obtained.

[0011] The motor of the present invention is formed by disposing the motor coil substrate of the present invention described above inside a cylindrical yoke and disposing a rotating shaft and a magnet inside the motor coil substrate.

[0012] In the motor of the embodiment of the present invention, the space factor of the coil in the cross section of the motor coil substrate is greater than 50% and less than 99%. The space factor of the coil conductor is ensured to be high. Therefore, high torque can be obtained. A high-performance motor can be obtained. Moreover, the torque can be increased in a small motor, and a high-performance motor can be obtained. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 It is a plan view schematically showing the coil substrate according to the embodiment.

[0014] Figure 2 It is a cross-sectional view schematically showing a coil substrate according to the embodiment.

[0015] Figure 3A It is a plan view schematically showing a U-phase coil in the coil substrate according to the embodiment.

[0016] Figure 3B It is a plan view schematically showing a V-phase coil in the coil substrate according to the embodiment.

[0017] Figure 3C It is a plan view schematically showing a W-phase coil in the coil substrate according to the embodiment.

[0018] Figure 4 It is a plan view of the U-phase, V-phase, and W-phase of the coil substrate of the comparative embodiment.

[0019] Figure 5 This is an explanatory diagram showing a coil substrate in a simplified manner according to the embodiment.

[0020] Figure 6 It is a perspective view schematically showing a motor coil substrate according to an embodiment.

[0021] Figure 7 It is an explanatory diagram schematically showing the positions of the respective terminals in the motor coil substrate according to the embodiment.

[0022] Figure 8 yes Figure 7 A magnified view of a portion of .

[0023] Fig. 9 It is a cross-sectional view schematically showing the motor according to the embodiment.

[0024] Fig.10 It is a top view schematically showing a coil substrate according to a modified example.

[0025] Fig.11 It is a bottom view schematically showing a coil substrate according to a modified example. DETAILED DESCRIPTION

[0026] [Implementation Method]

[0027] Figure 1 It is a top view showing the coil substrate 2 according to the embodiment. Figure 2 yes Figure 1 Cross-sectional view between II-II.

[0028] Figure 3A to Figure 3C The diagrams are plan views showing the U-phase coil 20U, the V-phase coil 20V, and the W-phase coil 20W, respectively.

[0029] Figure 4 It is a plan view comparing the U phase, V phase, and W phase of the coil substrate 2 . Figure 5 It is a simplified representation Figure 1 A top view of the coil substrate 2.

[0030] like Figure 1 As shown, the coil substrate 2 has a flexible substrate 10, a U-phase coil 20U, a V-phase coil 20V, a W-phase coil 20W, a U-phase terminal 40U, a V-phase terminal 40V, a W-phase terminal 40W, a plurality of inter-coil connecting wires 50U, 50V, 50W, a plurality of inter-phase connecting wires 60U, 60V and a return wire 70W.

[0031] The flexible substrate 10 is a resin substrate having a first surface 10F and a second surface 10B opposite to the first surface 10F. The flexible substrate 10 is formed using an insulating resin such as polyimide or polyamide. The flexible substrate 10 is flexible. The flexible substrate 10 is formed into a rectangular shape having four sides, namely, a first side E1 to a fourth side E4. The first side E1 is the length direction of the flexible substrate 10 ( Figure 1 The first side E1 and the second side E2 are both along the vertical direction (direction perpendicular to the length direction) and the short side of one end side. The second side E2 is the short side of the other end side in the length direction. Figure 1 The third side E3 and the fourth side E4 are both long sides extending in the length direction. As described in detail later, the motor coil substrate 550 is formed by winding the coil substrate 2 into a cylindrical shape (see Figure 6 ), the first surface 10F is arranged on the inner peripheral side, and the second surface 10B is arranged on the outer peripheral side.

[0032] The flexible substrate 10 includes a first region R1 on one end side (on the first side E1 side) in the longitudinal direction and a second region R2 adjacent to the first region R1. The second region R2 includes the second side E2.

[0033] The U-phase terminal 40U, the V-phase terminal 40V, and the W-phase terminal 40W are all formed on the third side E3 of the flexible substrate 10. In the embodiment, the U-phase terminal 40U and the W-phase terminal 40W are arranged in the first region R1. The V-phase terminal 40V is arranged in the second region R2. Figure 1As shown, the U-phase terminal 40U is connected to the starting end 20US of the U-phase coil 20U. At the same time, the U-phase terminal 40U is connected to the terminal 20WE of the W-phase coil 20W via the return line 70W. The V-phase terminal 40V is connected to the starting end 20VS of the V-phase coil 20V. At the same time, the V-phase terminal 40V is connected to the terminal 20UE of the U-phase coil 20U via the inter-phase connecting line 60U. The W-phase terminal 40W is connected to the starting end 20WS of the W-phase coil 20W. At the same time, the W-phase terminal 40W is connected to the terminal 20VE of the V-phase coil 20V via the inter-phase connecting line 60V. That is, in the embodiment, the U-phase coil 20U, the V-phase coil 20V, and the W-phase coil 20W are Δ-connected (refer to Figure 5 ). In other examples, the U-phase coil 20U, the V-phase coil 20V, and the W-phase coil 20W may be Y-connected or may be connected in any other manner.

[0034] The U-phase coil 20U, the V-phase coil 20V, and the W-phase coil 20W constitute the U-phase, the V-phase, and the W-phase of the three-phase motor, respectively.

[0035] like Figure 1 , Figure 3A and Figure 4 As shown, the starting end 20US of the U-phase coil 20U is arranged in the first region R1. The ending end 20UE of the U-phase coil 20U is arranged in the second region R2. Figure 3A As shown, the U-phase coil 20U includes six coils 31U, 32U, 33U, 34U, 35U, and 36U. The six coils 31U to 36U are arranged in sequence from the starting end 20US of the U-phase coil 20U toward the end 20UE (from the first region R1 toward the second region R2). The six coils 31U to 36U are connected to each other by the inter-coil connecting wire 50U.

[0036] Each of the six coils 31U to 36U is formed by forming a first wiring forming a half turn of one turn on the first surface 10F side, and forming a second wiring forming the remaining half turn on the second surface 10B side, and staggering adjacent turns. The first wiring and the second wiring are electrically connected via a via conductor penetrating the flexible substrate 10.

[0037] The first coil 31U, the third coil 33U, and the fifth coil 35U are wound at the first surface 10F from the starting end 20US of the U-phase coil 20U, and the winding end position (terminal end) is arranged on the second surface 10B. When the flexible substrate 10 is viewed from the first surface 10F, the coils 31U, 33U, and 35U are wound counterclockwise.

[0038] On the other hand, the winding start position (starting end) of the second coil 32U, the fourth coil 34U, and the sixth coil 36U from the starting end 20US of the U-phase coil 20U is arranged on the second surface 10B, and the winding end position (terminal end) is arranged on the first surface 10F. When the flexible substrate 10 is viewed from the first surface 10F side, the coils 32U, 34U, and 36U are wound clockwise.

[0039] like Figure 2 , Figure 3A as well as Figure 1 As shown, a portion of the wiring (second wiring) of the coil 31U overlaps a portion of the wiring (first wiring) of the adjacent coil 32U via the flexible substrate 10. Similarly, a portion of the wiring (second wiring) of the coil 32U overlaps a portion of the wiring (first wiring) of the adjacent coil 33U. A portion of the wiring (second wiring) of the coil 33U overlaps a portion of the wiring (first wiring) of the adjacent coil 34U. A portion of the wiring (second wiring) of the coil 34U overlaps a portion of the wiring (first wiring) of the adjacent coil 35U. A portion of the wiring (second wiring) of the coil 35U overlaps a portion of the wiring (first wiring) of the adjacent coil 36U.

[0040] like Figure 3A and Figure 1 As shown, the coil-to-coil connection wire 50U connecting the coil 31U and the coil 32U, the coil-to-coil connection wire 50U connecting the coil 33U and the coil 34U, and the coil-to-coil connection wire 50U connecting the coil 35U and the coil 36U are arranged on the second surface 10B. On the other hand, the coil-to-coil connection wire 50U connecting the coil 32U and the coil 33U, and the coil-to-coil connection wire 50U connecting the coil 34U and the coil 35U are arranged on the first surface 10F. The U-phase terminal 40U and the inter-phase connection wire 60U are arranged on the first surface 10F.

[0041] like Figure 1 , Figure 3B and Figure 4 As shown, the starting end 20VS of the V-phase coil 20V is arranged in the second region R2. The terminal end 20VE of the V-phase coil 20V is arranged in the first region R1. Figure 3B As shown, the V-phase coil 20V includes six coils 31V, 32V, 33V, 34V, 35V, and 36V. The six coils 31V to 36V are arranged in sequence from the starting end 20VS of the V-phase coil 20V toward the terminal 20VE (from the second region R2 toward the first region R1). The six coils 31V to 36V are connected to each other through the inter-coil connection wire 50V.

[0042] Each of the six coils 31V to 36V is formed by forming a first wiring forming a half turn of one turn on the first surface 10F side and forming a second wiring forming the remaining half turn on the second surface 10B side, and staggering adjacent turns. The first wiring and the second wiring are electrically connected via a via conductor penetrating the flexible substrate 10.

[0043] The first coil 31V, the third coil 33V, and the fifth coil 35V are wound at the first surface 10F from the starting end 20VS of the V-phase coil 20V, and the winding end position (terminal end) is arranged on the second surface 10B. When the flexible substrate 10 is viewed from the first surface 10F, the coils 31V, 33V, and 35V are wound counterclockwise.

[0044] On the other hand, the winding start position (starting end) of the second coil 32V, the fourth coil 34V, and the sixth coil 36V from the starting end 20VS of the V-phase coil 20V is arranged on the second surface 10B, and the winding end position (terminal end) is arranged on the first surface 10F. When the flexible substrate 10 is viewed from the first surface 10F side, the coils 32V, 34V, and 36V are wound clockwise.

[0045] like Figure 2 , Figure 3B as well as Figure 1 As shown, a portion of the wiring (first wiring) of the coil 31V overlaps a portion of the wiring (second wiring) of the adjacent coil 32V via the flexible substrate 10. Similarly, a portion of the wiring (first wiring) of the coil 32V overlaps a portion of the wiring (second wiring) of the adjacent coil 33V. A portion of the wiring (first wiring) of the coil 33V overlaps a portion of the wiring (second wiring) of the adjacent coil 34V. A portion of the wiring (first wiring) of the coil 34V overlaps a portion of the wiring (second wiring) of the adjacent coil 35V. A portion of the wiring (first wiring) of the coil 35V overlaps a portion of the wiring (second wiring) of the adjacent coil 36V.

[0046] like Figure 3B and Figure 1 As shown, the coil-to-coil connection wire 50V connecting the coil 31V and the coil 32V, the coil-to-coil connection wire 50V connecting the coil 33V and the coil 34V, and the coil-to-coil connection wire 50V connecting the coil 35V and the coil 36V are arranged on the second surface 10B. On the other hand, the coil-to-coil connection wire 50V connecting the coil 32V and the coil 33V and the coil-to-coil connection wire 50V connecting the coil 34V and the coil 35V are arranged on the first surface 10F. The V-phase terminal 40V and the inter-phase connection wire 60V are arranged on the first surface 10F.

[0047] like Figure 1 , Figure 3C and Figure 4As shown in FIG. 2 , the starting end 20WS of the W-phase coil 20W is arranged in the first region R1. The ending end 20WE of the W-phase coil 20W is arranged in the second region R2. Figure 3C As shown, the W-phase coil 20W includes six coils 31W, 32W, 33W, 34W, 35W, and 36W. The six coils 31W to 36W are arranged in sequence from the starting end 20WS of the W-phase coil 20W toward the terminal end 20WE (from the first region R1 toward the second region R2). The six coils 31W to 36W are connected to each other by the inter-coil connecting wire 50W.

[0048] Each of the six coils 31W to 36W is formed by forming a first wiring forming a half turn in one turn on the first surface 10F side and a second wiring forming the remaining half turn on the second surface 10B side, and staggering adjacent turns. The first wiring and the second wiring are electrically connected via a via conductor penetrating the flexible substrate 10 .

[0049] The first coil 31W, the third coil 33W, and the fifth coil 35W are wound at the first surface 10F from the starting end 20WS of the W-phase coil 20W, and the winding end position (end) is arranged on the second surface 10B. When the flexible substrate 10 is viewed from the first surface 10F, the coils 31W, 33W, and 35W are wound counterclockwise.

[0050] On the other hand, the winding start position (starting end) of the second coil 32W, the fourth coil 34W, and the sixth coil 36W from the starting end 20WS of the W-phase coil 20W is arranged on the second surface 10B, and the winding end position (terminal end) is arranged on the first surface 10F. When the flexible substrate 10 is viewed from the first surface 10F side, the coils 32W, 34W, and 36W are wound clockwise.

[0051] like Figure 2 , Figure 3C as well as Figure 1 As shown, a portion of the wiring (second wiring) of the coil 31W overlaps a portion of the wiring (first wiring) of the adjacent coil 32W via the flexible substrate 10. Similarly, a portion of the wiring (second wiring) of the coil 32W overlaps a portion of the wiring (first wiring) of the adjacent coil 33W. A portion of the wiring (second wiring) of the coil 33W overlaps a portion of the wiring (first wiring) of the adjacent coil 34W. A portion of the wiring (second wiring) of the coil 34W overlaps a portion of the wiring (first wiring) of the adjacent coil 35W. A portion of the wiring (second wiring) of the coil 35W overlaps a portion of the wiring (first wiring) of the adjacent coil 36W.

[0052] like Figure 3C and Figure 1As shown, the coil-to-coil connection wire 50W connecting the coil 31W and the coil 32W, the coil-to-coil connection wire 50W connecting the coil 33W and the coil 34W, and the coil-to-coil connection wire 50W connecting the coil 35W and the coil 36W are arranged on the second surface 10B. On the other hand, the coil-to-coil connection wire 50W connecting the coil 32W and the coil 33W, and the coil-to-coil connection wire 50W connecting the coil 34W and the coil 35W are arranged on the first surface 10F. The W-phase terminal 40W and the return wire 70W are arranged on the first surface 10F.

[0053] like Figure 3C , Figure 5 as well as Figure 1 As shown, the return line 70W connects between the terminal 20WE of the W-phase coil 20W and the U-phase terminal 40U. The return line 70W extends from the second region R2 to the first region R1.

[0054] Although not shown in the figure, the first surface 10F and the wiring of each coil 20U, 20V, 20W formed on the first surface 10F, the coil-to-coil connection wires 50U, 50V, 50W, the phase connection wires 60U, 60V, and the return wire 70W are covered with a resin insulation layer. Similarly, the wiring of each coil 20U, 20V, 20W formed on the second surface 10B and the coil-to-coil connection wires 50U, 50V, 50W are covered with a resin insulation layer.

[0055] like Figure 1 , Figure 3A to Figure 3C As shown, in the embodiment, the wiring of each coil 20U, 20V, 20W is configured into a hexagonal shape. In other examples, the wiring of each coil 20U, 20V, 20W can also be configured into any shape such as a circle (a perfect circle, an ellipse), a triangle, a quadrilateral (a square, a rectangle, a rhombus), a pentagon, a polygon above a heptagon, etc. In addition, it is not limited to that the configuration shape of the wiring of all coils is the same, and the configuration shape of the wiring between coils can also be different. The number of windings of a coil wiring can be more than 1 turn, preferably 3 to 7 turns. The coil wiring is formed by configuring half a turn on the first surface, configuring half a turn on the second surface, and connecting with a through hole. In addition, half a turn can be configured on the second surface, and half a turn can be configured on the first surface. At this time, half a turn refers to half of the coil wiring. In addition, 1 / 4 turn can be configured on the first surface, 1 / 4 turn can be configured on the second surface, connected by a through hole, and half a turn can be configured on the first surface or the second surface. In addition, the coil wiring can also be configured on the first surface or the second surface. At this time, the coil wiring on the first surface and the coil wiring on the second surface may overlap, may partially overlap, or may not overlap.

[0056] The coil substrate 2 of the embodiment is manufactured by any method. For example, the coil substrate 2 can also be formed by a covering method using a flexible substrate having a conductor layer (metal foil) as a starting material. In other examples, the coil substrate 2 can also be obtained by forming a metal layer on a flexible substrate using a printing or dispensing method. In another example, the coil substrate 2 can also be obtained by forming a flexible material and a metal layer using a 3D printer.

[0057] Figure 6 The coil substrate 2 ( Figure 1 to Figure 5 ) is a three-dimensional view of a motor coil substrate 550. Figure 6 As shown, by Figure 1 to Figure 5 ) is wound into a cylindrical shape to form a motor coil substrate 550 for a motor. When the coil substrate 2 is wound into a cylindrical shape, the first side E1 ( Figure 1 ) as a starting point, and winding a plurality of turns around an axis extending in a vertical direction (an axis extending parallel to the first side E1) as a center. In addition, the number of turns of the coil substrate is not particularly limited. When the coil substrate 2 is wound into a cylindrical shape, the first surface 10F of the flexible substrate 10 is arranged on the inner peripheral side, and the second surface 10B is arranged on the outer peripheral side.

[0058] Figure 7 The positions of the terminals when the motor coil substrate 550 is viewed along the axial direction are schematically shown. Figure 7 As shown, the U-phase terminal 40U, the V-phase terminal 40V, and the W-phase terminal 40W are arranged at intervals of approximately 120° in the circumferential direction. The U-phase terminal 40U and the W-phase terminal 40W are arranged on the inner circumferential surface. The V-phase terminal 40V is arranged on the outer circumferential surface. Figure 7 In the figure, the conductor layer in the wound state overlaps with the conductor layer outside it, but the conductor layer may overlap with a part of the conductor layer outside it, or the conductor layer may not overlap with the conductor layer outside it.

[0059] Figure 8 yes Figure 7 The enlarged view of part VIII in FIG. 1 shows an example of the terminal shape. Figure 8 As shown, conductor layers 100F and 100B of coils 20U, 20V, and 20W are formed on both sides of the flexible substrate 10, and insulating films 102F and 102B are formed on the conductor layers 100F and 100B of the coils 20U, 20V, and 20W. By forming the insulating films 102F and 102B, the conductor layers 100F and 100B are not exposed, and do not contact with adjacent conductor layers 100F and 100B or adjacent conductor layers 100F and 100B in the cross section when the coil substrate 2 is wound, so insulation is maintained. The insulating films 102F and 102B can be formed by printing liquid resin. An example of the resin is polyimide. In Figure 8Insulating films 102F and 102B are formed to follow the conductive layers 100F and 100B, but may also cover the upper surfaces of the conductive layers 100F and 100B and fill the space between the conductive layers 100F and 100B. The thickness of the insulating layers 102F and 102B is not particularly limited and may be formed to be about 1 μm or more and 30 μm or less. Figure 8 In the embodiment, the conductor layers 100F and 100B are symmetrically formed with the flexible substrate 10 interposed therebetween, but the conductor layers 100F and 100B may overlap partially with the flexible substrate 10 interposed therebetween, or the conductor layers 100F and 100B may not overlap with the flexible substrate 10 interposed therebetween. Figure 8 In the embodiment, the cross-sectional shape of the conductor layers 100F and 100B is a trapezoid, but the cross-sectional shape of the conductor layers 100F and 100B may also be a square or rectangular quadrilateral. The cross-sectional shapes of the conductor layers 100F and 100B may be the same or different.

[0060] At this time, the cross-section of the motor coil substrate 550 is composed of a flexible substrate 10, a conductor layer as wiring for each phase, and an insulating layer covering the conductor layer. At this time, the result of calculating the cross-sectional area of ​​all conductor layers in the cross-sectional area of ​​the motor coil substrate 550 becomes the space factor of the coil. At this time, the space factor of the coil in the cross-section of the motor coil substrate 550 is greater than 50% and less than 99%. The space factor of the coil conductor is ensured to be high. Therefore, when a motor is formed using the motor coil substrate 550 of the embodiment, high torque can be obtained. A high-performance motor can be obtained. At this time, the calculation method of the space factor of the coil is space factor = (sum of the cross-sectional areas of the conductor parts / cross-sectional area of ​​the coil) × 100.

[0061] exist Figure 7 The outer circumferential surface OC and the inner circumferential surface IC of the motor coil substrate 550 are shown in FIG. In an embodiment, the cylindricity of the outer circumferential surface OC of the motor coil substrate 550 is greater than 0.0 mm and less than 0.3 mm. If the cylindricity of the outer circumferential surface OC is greater than 0.0 mm and less than 0.3 mm, the motor coil substrate 550 will not roll evenly on a flat portion. By making the cylindricity of the outer circumferential surface OC greater than 0.0 mm and less than 0.3 mm, the bonding strength with the yoke is increased when the motor is formed. A motor with stable performance can be obtained. In addition, the cylindricity of the outer circumferential surface OC of the motor coil substrate 550 is preferably greater than 0.0 mm and less than 0.2 mm. By making the cylindricity of the outer circumferential surface OC greater than 0.0 mm and less than 0.2 mm, the bonding strength with the yoke is increased when the motor is formed, and it can be stable. Therefore, even when working as a motor, the motor coil substrate 550 will not be displaced, and a motor with stable performance can be obtained.

[0062] The cylindricity of the outer surface OC is measured by a V-block-based measurement method. That is, the motor coil substrate 550 is placed on a V-block, rotated once, and the difference in the direction perpendicular to the axis is measured at 5 different locations, and the average value is calculated to measure the cylindricity of the outer surface OC.

[0063] The space factor of the coils 20U, 20V, and 20W in the cross section of the motor coil substrate 550 is greater than 50% and less than 99%. By using the motor coil substrate 550 with a space factor of greater than 50% and less than 99%, a high-torque motor can be obtained. In addition, when the motor coil substrate 550 of the embodiment is applied to a small motor, the torque can be increased and a high-performance motor can be obtained. In addition, the small motor in this specification refers to a motor with an outer diameter of less than 50 mm.

[0064] In addition, the space factor of the coil in the cross section of the motor coil substrate 550 is preferably 55% or more and 90% or less. By using the motor coil substrate 550 with a coil space factor of 55% or more and 90% or less, a high-torque motor can be obtained. Furthermore, when the motor coil substrate 550 of the embodiment is applied to a small motor, the torque can be increased, and a high-performance motor can be obtained.

[0065] Furthermore, it is more preferable that the space factor of the coil in the cross section of the motor coil substrate 550 is greater than 60% and less than 80%. By ensuring that the space factor of the coil conductor is high, when it is wound into a cylindrical shape, it becomes a predetermined cylindrical shape. Furthermore, in a small motor, by ensuring that the space factor of the coil conductor is high, when it is wound into a cylindrical shape, it becomes a predetermined cylindrical shape, the torque can be increased, and a high-performance motor can be obtained.

[0066] The ratio of the wiring (i.e., the wiring of each coil 20U, 20V, 20W) to the total weight of the motor coil substrate 550 is 80.0% or more and 99.9% or less. By using the motor coil substrate 550 in which the wiring ratio is 80.0% or more and 99.9% or less of the total weight, a high torque motor can be obtained. At this time, the calculation method of the ratio of the wiring to the total weight of the motor coil substrate 550 is wiring ratio = (total weight of the conductor part / weight of the coil substrate) × 100.

[0067] In addition, the ratio of the wiring to the total weight of the motor coil substrate 550 is preferably 85.0% or more and 96.0% or less. Since the wiring ratio is 85.0% or more and 96.0% or less, the space factor of the coil conductor is high, and it becomes a predetermined cylindrical shape when wound into a cylinder. Furthermore, in a small motor, the space factor of the coil conductor is high, and it becomes a predetermined cylindrical shape when wound into a cylinder, which can increase the torque and obtain a high-performance motor.

[0068] The outer peripheral surface OC of the motor coil substrate 550 is formed by the flexible substrate 10, and the wiring of the coils 20U, 20V, 20W is not exposed. That is, an insulating layer covering the wiring is formed on the outermost periphery of the motor coil substrate 550. The outer peripheral surface OC of the motor coil substrate 550 is insulated from the outside.

[0069] When forming the motor coil substrate 550, the number of windings of the coil substrate 2 is arbitrary. The number of windings of the coil substrate 2 is preferably 2 or more and 10 or less. By setting the number of windings to 2 or more and 10 or less, the cylindricality of the outer peripheral surface OC of the formed motor coil substrate 550 is greater than 0.0 mm and less than 0.3 mm as described above. As a result, the reduction in motor performance can be suppressed.

[0070] The space factor of the coil in the cross section of the motor coil substrate 550 is greater than 50% and less than 99%, and the cylindricity of the outer peripheral surface OC of the motor coil substrate 550 is greater than 0.0 mm and less than 0.3 mm. In the motor coil substrate 550 of the embodiment of the present invention, when a motor is formed using the motor coil substrate 550 in which the space factor of the coil is greater than 50% and less than 99%, and the cylindricity of the outer peripheral surface OC is greater than 0.0 mm and less than 0.3 mm, the bonding strength with the yoke becomes higher when the motor is formed, and a high torque can be obtained. A high-performance motor can be obtained. In addition, when the motor coil substrate 550 of the embodiment is applied to a small motor, the torque can be increased to obtain a high-performance motor.

[0071] It is preferred that the space factor of the coil in the cross section of the motor coil substrate 550 is 55% or more and 90% or less, and the cylindricality of the outer peripheral surface OC of the motor coil substrate 550 is greater than 0.0 mm and less than 0.3 mm. By using a motor coil substrate 550 in which the space factor of the coil is 55% or more and 90% or less, and the cylindricality of the outer peripheral surface OC is greater than 0.0 mm and less than 0.3 mm, a high-torque motor can be obtained. A high-performance motor can be obtained. In addition, when the motor coil substrate 550 of the embodiment is applied to a small motor, the torque can be increased to obtain a high-performance motor.

[0072] Furthermore, it is preferred that the space factor of the coil in the cross section of the motor coil substrate 550 is greater than 60% and less than 80%, and the cylindricality of the outer peripheral surface OC of the motor coil substrate 550 is greater than 0.0 mm and less than 0.3 mm. The space factor of the coil in the cross section of the motor coil substrate 550 is greater than 60% and less than 80%, and the cylindricality of the outer peripheral surface OC of the motor coil substrate 550 is greater than 0.0 mm and less than 0.3 mm, thereby ensuring that the space factor of the coil conductor is high, and it becomes a prescribed cylindrical shape when wound into a cylindrical shape. When the motor is formed, the bonding strength with the yoke becomes higher, and a high torque can be obtained. A high-performance motor can be obtained. In addition, in a small motor, it is possible to ensure that the space factor of the coil conductor is high, and when it is wound into a cylindrical shape, it becomes a prescribed cylindrical shape, and the bonding strength with the yoke becomes higher when the motor is formed, which can increase the torque and obtain a high-performance motor. Furthermore, when the motor coil substrate 550 of the embodiment is applied to a small motor, the torque can be increased, thereby obtaining a high-performance motor.

[0073] It is more preferable that the space factor of the coil in the cross section of the motor coil substrate 550 is 60% or more and 80% or less, and the cylindricality of the outer peripheral surface OC of the motor coil substrate 550 is greater than 0.0mm and less than 0.2mm. The space factor of the coil in the cross section of the motor coil substrate 550 is 60% or more and 80% or less, and the cylindricality of the outer peripheral surface OC of the motor coil substrate 550 is greater than 0.0mm and less than 0.2mm, thereby ensuring that the space factor of the coil conductor is high, and when it is wound into a cylindrical shape, it becomes a prescribed cylindrical shape. When the motor is formed, the bonding strength with the yoke becomes high, and a high torque can be obtained. A high-performance motor can be obtained. Furthermore, in a small motor, the space factor of the coil conductor is also ensured to be high, and when it is wound into a cylindrical shape, it becomes a prescribed cylindrical shape, and the bonding strength with the yoke becomes high when the motor is formed, making it stable. Therefore, even when it works as a motor, the position of the motor coil substrate 550 does not shift, the torque can be increased, and a high-performance motor can be obtained. Furthermore, when the motor coil substrate 550 of the embodiment is applied to a small motor, the torque can be increased, thereby obtaining a high-performance motor.

[0074] The ratio of the wiring to the total weight of the motor coil substrate 550 is greater than 80.0% and less than 99.9%, and the cylindricality of the outer peripheral surface OC of the motor coil substrate 550 is greater than 0.0 mm and less than 0.3 mm. In the case of forming a motor using the motor coil substrate 550 of the embodiment in which the wiring accounts for a ratio of 80.0% to 99.9% of the total weight of the motor coil substrate 550 and the cylindricality of the outer peripheral surface OC is greater than 0.0 mm and less than 0.3 mm, the space factor of the coil is improved and high torque can be obtained. A high-performance motor can be obtained. In addition, when the motor coil substrate 550 of the embodiment is applied to a small motor, the torque can be improved to obtain a high-performance motor.

[0075] In addition, the ratio of the wiring to the total weight of the motor coil substrate 550 is greater than 85.0% and less than 96.0%, and the cylindricality of the outer peripheral surface OC of the motor coil substrate 550 is greater than 0.0 mm and less than 0.3 mm. In the case of forming a motor using the motor coil substrate 550 of the embodiment in which the wiring accounts for a ratio of 85.0% to 96.0% of the total weight of the motor coil substrate 550 and the cylindricality of the outer peripheral surface OC is greater than 0.0 mm and less than 0.3 mm, even if the ratio of the wiring is increased, it becomes a prescribed cylindrical shape. As a result, when the motor is formed, the bonding strength with the yoke becomes higher, the space factor of the coil is increased, and high torque can be obtained. A high-performance motor can be obtained. In addition, when the motor coil substrate 550 of the embodiment is applied to a small motor, the torque can be increased to obtain a high-performance motor.

[0076] Moreover, the ratio of the wiring to the total weight of the motor coil substrate 550 is greater than 85.0% and less than 96.0%, and the cylindricality of the outer peripheral surface OC of the motor coil substrate 550 is greater than 0.0mm and less than 0.2mm. In the case of forming a motor using the motor coil substrate 550 in which the wiring of the embodiment accounts for a ratio of greater than 85.0% and less than 96.0% of the total weight of the motor coil substrate 550 and the cylindricality of the outer peripheral surface OC is greater than 0.0mm and less than 0.2mm, even if the ratio of the wiring is increased and the space factor of the coil is increased, it becomes a prescribed cylindrical shape and a high torque can be obtained. As a result, the bonding strength with the yoke is increased when the motor is formed, making it stable. Therefore, even when working as a motor, the motor coil substrate 550 will not be displaced, and a motor with stable performance can be obtained. In addition, when the motor coil substrate 550 of the embodiment is applied to a small motor, the torque can be increased to obtain a high-performance motor.

[0077] The space factor of the coil in the cross section of the motor coil substrate 550 is greater than 50% and less than 99%, and the ratio of the wiring to the total weight of the motor coil substrate 550 is greater than 80.0% and less than 99.9%. In the motor coil substrate 550 of the embodiment, by using a motor coil substrate in which the space factor of the coil is greater than 50% and less than 99%, and the ratio of the wiring to the total weight of the motor coil substrate 550 is greater than 80.0% and less than 99.9%, the space factor of the coil can be increased to obtain high torque. A high-performance motor can be obtained. In addition, when the motor coil substrate 550 of the embodiment is applied to a small motor, the torque can be increased to obtain a high-performance motor.

[0078] Preferably, the space factor of the coil in the cross section of the motor coil substrate 550 is 55% to 90%, and the ratio of the wiring to the total weight of the motor coil substrate 550 is 85.0% to 96.0%. By using a motor coil substrate 550 in which the space factor of the coil is 55% to 90% and the ratio of the wiring to the total weight of the motor coil substrate 550 is 85.0% to 96.0%, the space factor of the coil can be increased, and a high-torque motor can be obtained. A high-performance motor can be obtained. In addition, when the motor coil substrate 550 of the embodiment is applied to a small motor, the torque can be increased, and a high-performance motor can be obtained.

[0079] Furthermore, it is preferred that the space factor of the coil in the cross section of the motor coil substrate 550 is 60% or more and 80% or less, and the ratio of the wiring to the total weight of the motor coil substrate 550 is 85.0% or more and 96.0% or less. The space factor of the coil is 60% or more and 80% or less, and the ratio of the wiring to the total weight of the motor coil substrate 550 is 85.0% or more and 96.0% or less, thereby ensuring that the space factor of the coil conductor is high and that it becomes a prescribed cylindrical shape when wound into a cylindrical shape. High torque can be obtained. A high-performance motor can be obtained. Moreover, in a small motor, the space factor of the coil conductor is high, and when wound into a cylindrical shape, it becomes a prescribed cylindrical shape, which can increase the torque and obtain a high-performance motor. Moreover, when the motor coil substrate 550 of the embodiment is applied to a small motor, the torque can be increased and a high-performance motor can be obtained.

[0080] The space factor of the coil in the cross section of the motor coil substrate 550 is 50% to 99%, the ratio of the wiring in the total weight of the motor coil substrate 550 is 80.0% to 99.9%, and the cylindricality of the outer peripheral surface OC of the motor coil substrate 550 is greater than 0.0 mm and less than 0.3 mm. In the motor coil substrate 550 of the embodiment, when a motor is formed using a motor coil substrate having a space factor of 50% to 99%, a ratio of the wiring in the total weight of the motor coil substrate 550 being 80.0% to 99.9%, and a cylindricality of the outer peripheral surface OC of the motor coil substrate 550 being greater than 0.0 mm and less than 0.3 mm, the space factor of the coil can be increased to obtain high torque. When the motor is formed, the bonding strength with the yoke becomes high, and high torque can be obtained. A high-performance motor can be obtained. Furthermore, when the motor coil substrate 550 of the embodiment is applied to a small motor, the torque can be increased, thereby obtaining a high-performance motor.

[0081] Furthermore, it is preferred that the space factor of the coil in the cross section of the motor coil substrate 550 is 55% or more and 90% or less, the ratio of the wiring to the total weight of the motor coil substrate 550 is 85.0% or more and 96.0% or less, and the cylindricality of the outer peripheral surface OC of the motor coil substrate 550 is greater than 0.0mm and less than 0.3mm. By using a motor coil substrate 550 in which the space factor of the coil is 55% or more and 90% or less, the ratio of the wiring to the total weight of the motor coil substrate 550 is 85.0% or more and 96.0% or less, and the cylindricality of the outer peripheral surface OC of the motor coil substrate 550 is greater than 0.0mm and less than 0.3mm, the space factor of the coil can be increased to a predetermined cylindrical shape, and a high-torque motor can be obtained. Therefore, even when working as a motor, a motor with stable performance can be obtained. Moreover, when the motor coil substrate 550 of the embodiment is applied to a small motor, the torque can be increased to obtain a high-performance motor.

[0082] In addition, it is preferred that the space factor of the coil in the cross section of the motor coil substrate 550 is 60% or more and 80% or less, and the ratio of the wiring in the total weight of the motor coil substrate 550 is 85.0% or more and 96.0% or less, and the cylindricality of the outer peripheral surface OC of the motor coil substrate 550 is greater than 0.0mm and less than 0.3mm. The space factor of the coil is 60% or more and 80% or less, and the ratio of the wiring in the total weight of the motor coil substrate 550 is 85.0% or more and 96.0% or less, and the cylindricality of the outer peripheral surface OC of the motor coil substrate 550 is greater than 0.0mm and less than 0.3mm, thereby ensuring that the space factor of the coil conductor is high and becomes a prescribed cylindrical shape when wound into a cylindrical shape. High torque can be obtained. As a result, the bonding strength with the yoke becomes high when the motor is formed. Therefore, even when working as a motor, a motor with stable performance can be obtained. When the motor coil substrate 550 of the embodiment is applied to a small motor, the torque can be increased, and a high-performance motor can be obtained.

[0083] In addition, it is preferred that the space factor of the coil in the cross section of the motor coil substrate 550 is 60% or more and 80% or less, and the ratio of the wiring in the total weight of the motor coil substrate 550 is 85.0% or more and 96.0% or less, and the cylindricality of the outer peripheral surface OC of the motor coil substrate 550 is greater than 0.0mm and less than 0.2mm. The space factor of the coil is 60% or more and 80% or less, and the ratio of the wiring in the total weight of the motor coil substrate 550 is 85.0% or more and 96.0% or less, and the cylindricality of the outer peripheral surface OC of the motor coil substrate 550 is greater than 0.0mm and less than 0.2mm, thereby ensuring that the space factor of the coil conductor is high and becomes a predetermined cylindrical shape when wound into a cylindrical shape. High torque can be obtained. As a result, the bonding strength with the yoke becomes high when the motor is formed, making it stable. Therefore, even when working as a motor, the motor coil substrate 550 will not be displaced, and a motor with stable performance can be obtained. When the motor coil substrate 550 of the embodiment is applied to a small motor, the torque can be increased, and a high-performance motor can be obtained.

[0084] The motor coil substrate 550 of the embodiment is used for a slotless motor. In other examples, the motor coil substrate 550 may be used for motors other than the slotless motor.

[0085] The diameter of the outer surface OC (outer diameter of the cross section) of the motor coil substrate 550 is 50 mm or less. The diameter of the outer surface OC (outer diameter of the cross section) of the motor coil substrate 550 is preferably 30 mm or less. By using a motor coil substrate 550 with a diameter of 50 mm or less to form a small motor, the reduction in motor performance can be effectively suppressed. The diameter of the outer surface OC of the motor coil substrate 550 is measured with a vernier caliper. In addition, Figure 1 In the illustrated embodiment, the space factor of the coil in the cross-sectional area of ​​the motor coil substrate 550 is 70%, the ratio of the wiring to the total weight of the motor coil substrate 550 is 93%, and the cylindricality of the outer peripheral surface OC is 0.1 mm.

[0086] Fig. 9 The motor coil substrate 550 ( Figure 6 to Figure 8 ) is a cross-sectional view of a motor 600. The motor 600 is formed by disposing a motor coil substrate 550 on the inner side of a yoke 560, and disposing a rotating shaft 580 and a magnet 570 fixed to the rotating shaft 580 on the inner side of the motor coil substrate 550. The motor 600 of the embodiment is a slotless motor.

[0087] As described above, the coil substrate 2 ( Figure 1 to Figure 5 )、Motor coil substrate 550( Figure 6 to Figure 8 )、Motor 600( Fig. 9 ) is described. As described above, the space factor of the coils 20U, 20V, and 20W in the cross section of the motor coil substrate 550 of the embodiment is greater than 50% and less than 99%. A high space factor is ensured. Therefore, when the motor 600 is formed using the motor coil substrate 550 of the embodiment, a high torque can be obtained. A high-performance motor 600 can be obtained.

[0088] [Modification of the embodiment]

[0089] Fig.10 and Fig.11 Modifications of the embodiments are described. Fig.10 1 is a plan view showing a coil substrate 102 according to a modified example. Fig.11 FIG. 1 is a bottom view showing a coil substrate 102 of a modified example. Fig.10 , Fig.11 As shown, in the modification example, the arrangement of the wiring of the coils 31U, 31V, and 31W constituting the U-phase coil 20U, the V-phase coil 20V, and the W-phase coil 20W is different from that in the embodiment.

[0090] In addition, Fig.10 , Fig.11In the figure, only coils 31U, 31V, and 31W are shown as the coils constituting the U-phase coil 20U, the V-phase coil 20V, and the W-phase coil 20W. However, in reality, the U-phase coil 20U, the V-phase coil 20V, and the W-phase coil 20W may be formed by a plurality of coils including the coils 31U, 31V, and 31W. Fig.10 , Fig.11 In the figure, the U-phase terminal 40U, the V-phase terminal 40V, the W-phase terminal 40W, the inter-coil connecting wires 50U, 50V, 50W, the plurality of inter-phase connecting wires 60U, 60V, and the return wire 70W are omitted.

[0091] The coil 31U constituting the U-phase coil 20U is provided with a coil-shaped first wiring 30UF ( Fig.10 ) and the coil-shaped second wiring 30UB ( Fig.11 ). The first wiring 30UF and the second wiring 30UB are electrically connected via a via-hole conductor 81U that passes through the flexible substrate 10. Similarly, the coil 20V constituting the V phase is composed of the first wiring 30VF and the second wiring 30VB. The first wiring 30VF and the second wiring 30VB are electrically connected via a via-hole conductor 81V. The coil 20W constituting the W phase is composed of the first wiring 30WF and the second wiring 30WB. The first wiring 30WF and the second wiring 30WB are electrically connected via a via-hole conductor 81W.

[0092] like Fig.10 As shown in FIG. 1 , the first wiring 30UF is formed in a spiral shape (hexagonal spiral shape) that turns clockwise from the outer circumference to the inner circumference. The via conductor 81U is formed at the inner circumference side end of the first wiring 30UF. Fig.11 As shown in FIG. 1 , the second wiring 30UB is formed into a spiral shape (hexagonal spiral shape) that turns leftward from the outer circumference to the inner circumference. The via conductor 81U is formed at the inner circumference side end of the second wiring 30UB. The first wiring 30UF and the second wiring 30UB are formed into a spiral shape with the same winding direction when viewed from the same surface. The first wiring 30UF and the second wiring 30UB overlap with the flexible substrate 10. The first wiring 30UF and the second wiring 30UB function as one coil 31U electrically connected in series.

[0093] The first wiring 30VF and the second wiring 30VB and the first wiring 30WF and the second wiring 30WB have the same relationship as the first wiring 30UF and the second wiring 30UB described above. The first wiring 30VF and the second wiring 30VB are formed into a spiral shape with the same winding direction when viewed from the same surface. The first wiring 30VF and the second wiring 30VB overlap with the flexible substrate 10. The first wiring 30VF and the second wiring 30VB function as one coil 31V electrically connected in series. The first wiring 30WF and the second wiring 30WB are formed into a spiral shape with the same winding direction when viewed from the same surface. The first wiring 30WF and the second wiring 30WB overlap with the flexible substrate 10. The first wiring 30WF and the second wiring 30WB function as one coil 31W electrically connected in series.

[0094] Although not shown in the figure, the first surface 10F and the first wirings 30UF, 30VF, 30WF are covered with a resin insulating layer. Similarly, the second surface 10B and the second wirings 30UB, 30VB, 30WB are covered with a resin insulating layer. The small motor in this specification refers to a motor with an outer diameter of 50 mm or less.

[0095] like Fig.10 , Fig.11 As shown, in the modified example, the wiring of each coil 20U, 20V, 20W is configured in a hexagonal shape. In other examples, the wiring of each coil 20U, 20V, 20W can also be configured in any shape such as a circle (a perfect circle, an ellipse), a triangle, a quadrilateral (a square, a rectangle, a rhombus), a pentagon, a polygon with a heptagon or more. In addition, the wiring configuration shape of all coils is not limited to the same, and the wiring configuration shape between coils can also be different.

[0096] The coil substrate 102 of the modified example can be manufactured by any method. For example, the coil substrate 2 can also be formed by a covering method using a flexible substrate having a conductor layer (metal foil) as a starting material. In other examples, the coil substrate 102 can also be obtained by forming a metal layer on a flexible substrate using a printing or dispensing method. In another example, the coil substrate 102 can be obtained by forming a flexible material and a metal layer in a 3D printer.

[0097] The motor coil substrate 550 (see FIG. 1 ) for use in a motor is formed by winding the coil substrate 102 of the modified example into a cylindrical shape. Figure 6 to Figure 8 ). The motor coil substrate 550 formed by the coil substrate 102 of the modified example also has the same features as the motor coil substrate 550 of the embodiment. Therefore, the motor coil substrate 550 of the modified example can also exert the same effects as the motor coil substrate 550 of the embodiment. Fig.10 , Fig.11In the modified example shown, the space factor of the coil in the cross-sectional area of ​​the motor coil substrate 550 is 65%. The ratio of the wiring to the total weight of the motor coil substrate 550 is 91%. The outer peripheral surface OC (see Figure 7 ) has a cylindricity of 0.1 mm.

[0098] Description of symbols

[0099] 2, 102: coil substrate; 10: flexible substrate; 20U: U-phase coil; 20V: V-phase coil; 20W: W-phase coil; 550: motor coil substrate; 560: yoke; 570: magnet; 580: rotating shaft; 600: motor; IC: inner circumference; OC: outer circumference.

Claims

1. A motor coil substrate, comprising: a flexible substrate having a first surface and a second surface opposite to the first surface; and a plurality of coils formed by wiring arranged on the first surface and the second surface, The motor coil substrate is formed into a cylindrical shape by winding in a circumferential direction around an axis extending in a direction perpendicular to the longitudinal direction, starting from a first end of the flexible substrate in the longitudinal direction. in, A space factor of the coil in a cross section of the motor coil substrate is 50% or more and 99% or less.

2. The motor coil substrate according to claim 1, wherein: The space factor is greater than or equal to 55% and less than or equal to 90%.

3. The motor coil substrate according to claim 1, wherein: The outer peripheral surface is formed by the flexible substrate, The wiring is not exposed.

4. The motor coil substrate according to claim 1, wherein: The coil includes a first wiring formed in a half turn on the first surface, a second wiring formed in a half turn on the second surface, and a via conductor connecting the first wiring and the second wiring.

5. The motor coil substrate according to claim 1, wherein: The coil includes a first wiring formed in a spiral shape on the first surface, a second wiring formed in a spiral shape on the second surface, and a via conductor connecting the first wiring and the second wiring.

6. The motor coil substrate according to claim 1, wherein: The motor coil substrate is used for a slotless motor.

7. The motor coil substrate according to claim 1, wherein: The outer diameter of the cross section of the motor coil substrate is 50 mm or less. 8 . A motor formed by arranging the motor coil according to claim 1 inside a cylindrical yoke and arranging a rotating shaft and a magnet inside the motor coil.

Images