Disc type motor based on PCB stator and manufacturing method thereof

Abstract

The invention discloses a disc type motor based on a PCB stator, which comprises a multi-layer PCB substrate, a snake-shaped radial winding is etched on the front end surface of the multi-layer PCB substrate, a magnet yoke is pressed in the middle of the interior of the multi-layer PCB substrate, a micro-channel is processed in the magnet yoke, a nano-ceramic coating is arranged on the front end surface of the multi-layer PCB substrate, and the nano-ceramic coating is arranged on the front end surface of the multi-layer PCB substrate. A plurality of aluminum alloy heat dissipation fins are welded to the rear end face of the multi-layer PCB substrate, the motor relates to the technical field of motors, the design of the multi-layer PCB substrate structure is adopted, surface deposition nano ceramic coating treatment is carried out, and therefore interlayer voltage withstanding gt is achieved; the service life can be prolonged by three times under the 1kV and humid and hot environment, the temperature rise can be reduced by 40% through the design of the micro-channel and the metal substrate and the assistance of the aluminum alloy heat dissipation fins, and the torque density can be improved by 30% by etching the snakelike radial winding to form the Halbach array matched magnet yoke.

Description

Technical Field

[0001] The present invention relates to the technical field of motors, and in particular to a disc-type motor based on a PCB stator and a manufacturing method thereof. Background Art

[0002] A motor control board, also known as a motor PCB (printed circuit board), is a key component used to control the operation of a motor. Through precise electronic components and circuit design, it enables accurate control of the motor's speed, direction, and torque. These boards are widely used in a variety of industrial equipment, household appliances, automotive electronics, and robotics, and are an indispensable part of modern motor systems.

[0003] For example, the publication number CN202020621879.2, a real-time detection device for motor parameters based on an NFC chip, discloses an NFC-based motor detection device but does not involve innovation in the stator structure;

[0004] At the same time, traditional disc motor stators are mostly wound with enameled wire, so they have the following defects: low insulation reliability, that is, the insulation between windings is easily aged due to vibration or humid and hot environment; poor heat dissipation efficiency, that is, the copper wire has a long heat dissipation path and the efficiency decreases significantly under high temperature; uneven magnetic flux distribution, that is, serious magnetic leakage and limited torque density. Summary of the Invention

[0005] In response to the shortcomings of the existing technology, the present invention provides a disc motor based on a PCB stator and a manufacturing method thereof, which solves the problems of low insulation reliability, poor heat dissipation efficiency and uneven magnetic flux distribution of traditional disc motor stators in the existing technology.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solutions: a disc motor based on a PCB stator, comprising a multi-layer PCB substrate, the front end surface of the multi-layer PCB substrate being etched with a serpentine radial winding, a magnetic yoke being press-fitted into the middle of the multi-layer PCB substrate, and microchannels being machined into the interior of the magnetic yoke, the front end surface of the multi-layer PCB substrate being provided with a nano-ceramic coating, and the rear end surface of the multi-layer PCB substrate being welded with a plurality of aluminum alloy heat dissipation fins.

[0007] Preferably, the number of layers of the multi-layer PCB substrate is greater than or equal to 4.

[0008] Preferably, the plurality of aluminum alloy heat dissipating fins are distributed equidistantly in a ring shape with the midpoint of the multi-layer PCB substrate as the center.

[0009] A method for manufacturing a disc motor based on a PCB stator includes the following manufacturing steps:

[0010] S1, laminate thick copper foil through FR or polyimide insulation layer to form a multi-layer PCB substrate. Each layer of copper foil is etched into a serpentine radial winding, and the layers are electrically paralleled through blind or buried vias with an accuracy of ±5μm.

[0011] S2, press-fit the yoke into the middle through-hole of the multi-layer PCB substrate and align it with the winding to close the magnetic circuit;

[0012] S3, a micro-channel is integrated inside the magnetic yoke to allow coolant to directly contact the copper foil;

[0013] S4, using 3D printing to deposit nano-ceramic coating on the winding surface;

[0014] S5, vacuum impregnation with epoxy resin followed by vacuum curing;

[0015] S6, solder aluminum alloy heat sink fins on the back of the multi-layer PCB substrate or connect external liquid cooling pipes.

[0016] Beneficial effects

[0017] The present invention provides a disc motor based on a PCB stator and a manufacturing method thereof, which has the following beneficial effects:

[0018] Insulation performance: The multi-layer PCB substrate structure is designed with a surface-deposited nano-ceramic coating, resulting in an interlayer withstand voltage of >1kV and a lifespan that can be tripled in hot and humid environments.

[0019] Heat dissipation efficiency: The design of micro-channel + metal substrate, supplemented by aluminum alloy heat dissipation fins, can reduce the temperature rise by 40%;

[0020] Magnetic flux density: Etched with serpentine radial windings to form a Halbach array, combined with a magnetic yoke, it can increase torque density by 30%. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a structural schematic diagram of the present invention.

[0022] Figure 2 It is a rear view of the present invention.

[0023] Figure 3 It is a partially enlarged schematic diagram of the present invention.

[0024] In the figure: 1. Multi-layer PCB substrate; 2. Serpentine radial winding; 3. Magnetic yoke; 4. Microchannel; 5. Nano-ceramic coating; 6. Aluminum alloy heat sink fins. DETAILED DESCRIPTION

[0025] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0026] See also Figure 1-3 The present invention provides a technical solution: a disc motor based on a PCB stator, comprising a multi-layer PCB substrate 1, wherein a serpentine radial winding 2 is etched on the front end surface of the multi-layer PCB substrate 1, a magnetic yoke 3 is press-fitted into the middle of the multi-layer PCB substrate 1, and a micro-channel 4 is machined inside the magnetic yoke 3, a nano-ceramic coating 5 is provided on the front end surface of the multi-layer PCB substrate 1, and a plurality of aluminum alloy heat dissipation fins 6 are welded to the rear end surface of the multi-layer PCB substrate 1.

[0027] This embodiment is further configured such that the number of layers of the multi-layer PCB substrate 1 is greater than or equal to 4;

[0028] The multi-layer PCB substrate 1 is at least 4 layers of thick copper foil (≥105 μm).

[0029] This embodiment is further configured such that the plurality of aluminum alloy heat dissipating fins 6 are distributed equidistantly in a ring shape with the midpoint of the multi-layer PCB substrate 1 as the center.

[0030] A disc motor based on a PCB stator includes the following manufacturing steps:

[0031] S1, thick copper foil is laminated through FR4 or polyimide insulation layer to form a multi-layer PCB substrate 1. Each layer of copper foil is etched into serpentine radial winding 2. The layers are electrically connected in parallel through blind or buried vias with an accuracy of ±5μm.

[0032] S2, press-fitting the magnetic yoke 3 into the middle through hole of the multi-layer PCB substrate 1 and aligning it with the winding to close the magnetic circuit;

[0033] S3, a micro channel 4 is integrated inside the magnetic yoke 3, and a coolant is passed into the micro channel to directly contact the copper foil;

[0034] S4, using 3D printing to deposit nano-ceramic coating 5 on the winding surface;

[0035] S5, vacuum impregnation with epoxy resin followed by vacuum curing;

[0036] S6, welding aluminum alloy heat sink fins 6 on the back side of the multi-layer PCB substrate 1 or connecting an external liquid cooling pipeline;

[0037] After the yoke 3 is pressed onto the multi-layer PCB substrate 1, the gap can be filled with silver paste. The yoke 3 can be made of sendust material. A 4-layer 2oz copper foil PCB can be used. Concentric spirals with a line width of 0.3mm and a spacing of 0.5mm can be laser-etched to form a serpentine radial winding 2. Aluminum alloy heat sink fins 6 are then welded to the back of the multi-layer PCB substrate 1 to achieve heat dissipation and cooling. An aluminum-based PCB substrate can also be used, with a 1mm deep micro-channel milled on the back to connect to an external liquid cooling pipeline.

[0038] It is worth noting that the standard parts used in the present invention can all be purchased from the market, and special-shaped parts can be customized according to the description in the specification and the drawings. The specific connection methods of each part adopt conventional means such as bolts, rivets, and welding in the prior art. The models of electrical structural equipment involved can be selected according to user needs and only need to meet the use requirements of this application. In addition, the circuit connection adopts the conventional connection method in the prior art. The control, current detection, position feedback, predicted voltage synchronization and parameter adjustment of electrical equipment are all prior art and will not be repeated here. The contents not described in detail in this specification belong to the prior art known to professional and technical personnel in this field.

[0039] By those skilled in the art, the components in this case are connected in sequence. The specific connection and operation sequence should refer to the following working principle. The detailed connection means are well-known technologies in this field. The following mainly introduces the working principle and process.

[0040] Example: Thick copper foil is laminated through FR4 or polyimide insulation layers to form a multilayer PCB substrate 1. Each layer of copper foil is etched into a serpentine radial winding 2. Electrical parallel connection is achieved between layers through blind or buried vias with an accuracy of ±5μm. A magnetic yoke 3 is press-fitted into the middle through-hole of the multilayer PCB substrate 1 and aligned with the winding to close the magnetic circuit. Microchannels 4 are integrated within the magnetic yoke 3, and coolant is passed through to directly contact the copper foil. A nano-ceramic coating 5 is deposited on the surface of the winding using 3D printing. Epoxy resin is vacuum-impregnated and then vacuum-cured. Aluminum alloy heat sink fins 6 are soldered to the back of the multilayer PCB substrate 1 or connected to an external liquid cooling line. Test results show that the insulation resistance reaches >100MΩ (500V DC) and the temperature rise is ≤25K at rated power.

[0041] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "include", "comprises" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device that includes a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions. The sentence "including an element defined by..." does not exclude the presence of other identical elements in the process, method, article or device that includes the element."

[0042] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A disc motor based on a PCB stator, comprising a multi-layer PCB substrate (1), characterized in that: The front end face of the multi-layer PCB substrate (1) is etched with a serpentine radial winding (2), a magnetic yoke (3) is pressed into the middle of the interior of the multi-layer PCB substrate (1), and a micro-channel (4) is machined inside the magnetic yoke (3), the front end face of the multi-layer PCB substrate (1) is provided with a nano-ceramic coating (5), and the rear end face of the multi-layer PCB substrate (1) is welded with a plurality of aluminum alloy heat dissipation fins (6).

2. The disc motor based on PCB stator according to claim 1, characterized in that: The number of layers of the multi-layer PCB substrate (1) is greater than or equal to 4.

3. The disc motor based on PCB stator according to claim 1, characterized in that: The plurality of aluminum alloy heat dissipation fins (6) are distributed in a circular manner at equal intervals with the midpoint of the multi-layer PCB substrate (1) as the center.

4. A method for manufacturing a disc motor based on a PCB stator, based on the disc motor based on a PCB stator according to claim 1, characterized in that: The manufacturing steps include: S1, a thick copper foil is laminated through an FR4 or polyimide insulating layer to form a multi-layer PCB substrate (1), each layer of copper foil is etched into a serpentine radial winding (2), and the layers are electrically connected in parallel through blind or buried vias with an accuracy of ±5μm; S2, press-fitting a magnetic yoke (3) at the middle through hole of the multi-layer PCB substrate (1) and aligning it with the winding to close the magnetic circuit; S3, a micro-channel (4) is integrated inside the magnetic yoke (3), and a coolant is passed through the micro-channel to directly contact the copper foil; S4, depositing nano-ceramic coating on the winding surface using 3D printing (5); S5, vacuum impregnation with epoxy resin followed by vacuum curing; S6, welding aluminum alloy heat dissipation fins (6) on the back side of the multi-layer PCB substrate (1) or connecting an external liquid cooling pipeline.

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