Coil substrate, motor coil substrate, and motor

Abstract

To provide a coil substrate in which a cross-sectional shape of a motor coil substrate can be formed into a true circular shape, and a motor coil substrate and a motor using the coil substrate.SOLUTION: A coil substrate according to an embodiment has a resin substrate having a first surface 10F and a second surface 10B opposite to the first surface, and a plurality of coil wires arranged along the longitudinal direction of the resin substrate, and is wound into a substantially cylindrical shape to form a motor coil substrate. A first side on one end side in the longitudinal direction of the resin substrate is set as a winding start, and the coil substrate is wound by a plurality of times about an axis extending in parallel with the first side from the winding start as a start point. The plurality of coil wires include a first coil wire that is located on the outermost layer and is located closest to the winding end when wound in a substantially cylindrical shape, and a second coil wire that is adjacent to the first coil wire on the outermost layer. The wire width W1 of the first coil wire and the wire width W2 of the second coil wire satisfy the relationship of Expression 1. W1<W2 ... Expression 1.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The technology disclosed in this specification relates to a coil substrate, a coil substrate for a motor, and a motor. [Background technology]

[0002] Patent Document 1 discloses a coil body formed by winding a printed wiring board on which a wiring pattern is formed multiple times to form a cylindrical shape. The printed wiring board in Patent Document 1 is wound so that the winding end located on the outermost layer exceeds the circumferential position of the winding start end located on the innermost layer. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2020 / 194627 Summary of the Invention

[0004] <Issues of Patent Document 1> In the technology of Patent Document 1, the winding end located on the outermost layer of the printed wiring board is wound so that it exceeds the circumferential position of the winding start end, making it difficult to form a cylindrical shape. When winding a printed wiring board to form a cylindrical shape, the portion of the printed wiring board that overlaps the winding start end located on the innermost layer from the outer layer side becomes a protruding shape. In particular, the protruding shape becomes clear on the outermost layer, and the coil body becomes elliptical. If a coil body with an elliptical shape is used in a motor, it will be difficult to fit inside the motor. As a result, it is thought that motor performance will deteriorate. [Means for solving the problem]

[0005] The present invention relates to a resin substrate having a first surface and a second surface opposite to the first surface, and a coil substrate having a plurality of coil wirings arranged along the longitudinal direction of the resin substrate, which is wound in a substantially cylindrical shape to form a coil substrate for a motor. Starting from a first side on one end side in the longitudinal direction of the resin substrate and ending at a second side on the other end side in the longitudinal direction of the resin substrate, it is wound a plurality of times in the circumferential direction around an axis extending parallel to the first side starting from the start of winding. Among the plurality of coil wirings, it has a first coil wiring located in the outermost layer in the state of being wound in the substantially cylindrical shape and closest to the end of winding, and a second coil wiring adjacent to the first coil wiring in the outermost layer. The wiring width W1 of the first coil wiring and the wiring width W2 of the second coil wiring satisfy the relationship of Formula 1. W1 < W2 ···· Formula 1

[0006] The coil substrate of the present invention is wound in a substantially cylindrical shape to form a coil substrate for a motor. In the state where the coil substrate is wound in a substantially cylindrical shape, by making the wiring width W1 of the first coil wiring located in the outermost layer and closest to the end of winding smaller than the wiring width W2 of the second coil wiring adjacent to the first coil wiring in the outermost layer, the length of the vicinity of the end of winding of the coil substrate can be shortened. As a result, the coil substrate is wound in a substantially cylindrical shape because the end of winding does not exceed a virtual line extended radially outward from the start of winding to the motor coil substrate, and thus no protrusion shape is formed. Therefore, the cross-sectional shape of the motor coil substrate can be made into a perfect circle shape. When the motor coil substrate having a perfect circle shape is accommodated in the housing of the motor, the gap between the housing and the substrate becomes uniform. By making the gap uniform, even when the motor is operated, heat is less likely to accumulate and the deterioration of motor performance is suppressed.

[0007] The coil substrate of the present invention is such that the wiring width W1 of the first coil wiring and the wiring width W2 of the second coil wiring satisfy the relationship of Formula 2. 1 / 2 ≦ W1 / W2 < 1 ···· Formula 2

[0008] By making W1 / W2<1, it is possible to prevent the end of the winding from overlapping the imaginary line. Furthermore, by making 1 / 2≦W1 / W2, it is possible to prevent the wiring width of the coil wiring located closest to the end of the winding on the outermost layer from becoming too small, which would increase wiring resistance and reduce current, thereby ensuring motor performance.

[0009] The coil substrate of the present invention has a third coil wiring that is located in the innermost layer among the multiple coil wirings when wound in the approximately cylindrical shape, and the wiring width W1 of the first coil wiring and the wiring width W3 of the third coil wiring satisfy the relationship of Equation 3. W1=W3...Formula 3

[0010] When forming a motor coil substrate by winding a coil substrate in a substantially cylindrical shape, the outer layers have larger wiring widths of the coil wiring because coil wiring of the same phase is arranged to overlap radially. In the present invention, the wiring width W1 of the first coil wiring located in the outermost layer and closest to the winding end is made equal to the wiring width W3 of the third coil wiring located in the innermost layer. This ensures that the wiring width W1 of the first coil wiring is smaller than the wiring width W2 of the second coil wiring. Furthermore, since the wiring width W1 of the third coil wiring in the innermost layer is made equal to the wiring width W3, the design of the coil wiring and the manufacturing of the coil substrate are facilitated.

[0011] In the coil substrate of the present invention, an imaginary line, which is a straight line connecting the winding start and the cylindrical center of the coil substrate, is provided on the cylindrical cross section of the motor coil substrate, and the winding end does not exceed the imaginary line.

[0012] The coil substrate of the present invention is wound into a substantially cylindrical shape because the end of the winding does not extend beyond an imaginary line connecting the start of the winding and the center of the cylindrical coil substrate, thereby preventing the formation of a protrusion. As a result, the cross-sectional shape of the motor coil substrate can be made to be a perfect circle. When the motor coil substrate with a perfect circle shape is housed in the motor housing, the gap between the housing and the substrate becomes uniform. By making the gap uniform, heat is less likely to build up even when the motor is operating, and a decrease in motor performance is suppressed.

[0013] In the coil substrate of the present invention, the multiple coil wirings have U-phase, V-phase, and W-phase coil wirings, and the circumferential distance (d) between the virtual line and the end of winding is greater than 0 and is equal to or less than the circumferential length (D) of any one of the U-phase, V-phase, and W-phase coil wirings located in the innermost layer when wound in the approximately cylindrical shape.

[0014] In the coil substrate of the present invention, the winding end can be prevented from overlapping with the imaginary line by making the circumferential distance (d) between the imaginary line and the winding end greater than 0. Furthermore, by making the circumferential distance (d) between the imaginary line and the winding end equal to or less than the circumferential length (D) of the one-phase coil wiring located in the innermost layer, it is possible to prevent an increase in wiring resistance and a decrease in current caused by the wiring width of the coil wiring located closest to the winding end in the outermost layer becoming too small, thereby ensuring motor performance.

[0015] In the coil substrate of the present invention, a first insulating layer is formed on the first surface of the resin substrate, a first edge on one longitudinal end side of the resin substrate is the edge on one longitudinal end side of the first insulating layer, and the edge on one end side of the first insulating layer is the start of winding, a second edge on the other longitudinal end side of the resin substrate is the edge on the other longitudinal end side of the first insulating layer, and the edge on the other end side of the first insulating layer is the end of winding, and the imaginary line is a straight line connecting the start of winding of the first insulating layer and the cylindrical center of the coil substrate, and when the coil substrate is wound into an approximately cylindrical shape, the end of winding of the first insulating layer does not exceed the imaginary line.

[0016] In the coil substrate of the present invention, a first insulating layer is formed on a first surface of a resin substrate. When the coil substrate is wound into a substantially cylindrical shape to form a motor coil substrate, the winding is performed so that the end of the first insulating layer does not extend beyond an imaginary line connecting the start of the winding of the first insulating layer and the cylindrical center of the coil substrate. This allows the cross-sectional shape of the motor coil substrate to be a perfect circle. When the motor coil substrate with a perfect circle shape is placed in a motor housing, the gap between the housing and the substrate becomes uniform. By making the gap uniform, heat is less likely to build up even when the motor is operating, and a decrease in motor performance is suppressed.

[0017] In the coil substrate of the present invention, a second insulating layer is formed on the second surface of the resin substrate, a first edge at one end of the longitudinal direction of the resin substrate is the edge at one end of the longitudinal direction of the second insulating layer, and the edge at one end of the second insulating layer is the start of winding, a second edge at the other end of the longitudinal direction of the resin substrate is the edge at the other end of the longitudinal direction of the second insulating layer, and the edge at the other end of the second insulating layer is the end of winding, and the imaginary line is a straight line connecting the start of winding of the second insulating layer and the cylindrical center of the coil substrate, and when the coil substrate is wound into an approximately cylindrical shape, the end of winding of the second insulating layer does not exceed the imaginary line.

[0018] In the coil substrate of the present invention, a second insulating layer is formed on the second surface of the resin substrate. When the coil substrate is wound into a substantially cylindrical shape to form the motor coil substrate, the winding is performed so that the end of the second insulating layer does not extend beyond an imaginary line connecting the start of the winding of the second insulating layer and the cylindrical center of the coil substrate. This allows the cross-sectional shape of the motor coil substrate to be a perfect circle. When the motor coil substrate with a perfect circle shape is placed in the motor housing, the gap between the housing and the substrate becomes uniform. By making the gap uniform, heat is less likely to build up even when the motor is operating, and a decrease in motor performance is suppressed.

[0019] In the coil substrate of the present invention, the coil wiring forms a half turn with the first coil wiring on the first surface and a half turn with the second coil wiring on the second surface, and the first coil wiring and the second coil wiring are connected by a through hole or a via hole.

[0020] In the coil substrate of the present invention, a coil is formed by electrically connecting a half turn of the first coil wiring on the first surface and a half turn of the second coil wiring on the second surface via a through hole or a via hole. A coil substrate having half-turn coil wiring formed on each of the first and second surfaces can be used to form a motor coil substrate having a perfectly circular cross section.

[0021] In the coil substrate of the present invention, the coil wiring forms a spiral with the first coil wiring on the first surface and a spiral with the second coil wiring on the second surface, and the first coil wiring and the second coil wiring are connected by a through hole or a via hole.

[0022] In the coil substrate of the present invention, a coil is formed by electrically connecting a spiral of first coil wiring on a first surface and a spiral of second coil wiring on a second surface via a through hole or a via hole. A coil substrate having spiral coil wiring formed on the first surface or the second surface can be used to form a coil substrate for a motor having a perfectly circular cross section.

[0023] The motor coil substrate of the present invention is formed by winding the coil substrate into the approximately cylindrical shape. According to the motor coil substrate of the present invention, the cross-sectional shape can be made into a perfect circle. When the motor coil substrate with a perfect circle shape is housed in a motor housing, the gap between the housing and the substrate becomes uniform. By making the gap uniform, heat is less likely to build up even when the motor is operating, and a decrease in motor performance is suppressed.

[0024] The motor of the present invention is formed by providing one of the motor coil substrate and the magnet on the rotor and the other on the stator. By forming a motor using a motor coil substrate with a perfect circular shape, a high-performance motor can be obtained. [Brief explanation of the drawings]

[0025] [Figure 1] FIG. 2 is a top view showing the coil substrate of the embodiment. [Figure 2] FIG. 4 is a cross-sectional view taken along line II-II in FIGS. 1 and 3. [Figure 3] FIG. 2 is a bottom view showing the coil substrate of the embodiment. [Figure 4] 1 is a side view of a motor coil substrate using the coil substrate of the embodiment, viewed from the central axis direction. [Figure 5]5 is a partially enlarged view of the vicinity of the imaginary line of the motor coil substrate shown in FIG. 4. [Figure 6] 5 is a partially enlarged view of the vicinity of the imaginary line of the motor coil substrate shown in FIG. 4. [Figure 7] 1 is a cross-sectional view schematically showing a motor using a motor coil substrate according to an embodiment of the present invention; [Figure 8] 1 and 3. FIG. 4 is a cross-sectional view of the coil substrate of the first modified example, taken along the line II-II shown in FIG. [Figure 9] 10 is a side view of a motor coil substrate using the coil substrate of the first modified example, viewed from the central axis direction. FIG. [Figure 10] 10 is a partially enlarged view of the motor coil substrate shown in FIG. 9 in the vicinity of the imaginary line. [Figure 11] FIG. 10 is a top view showing a coil substrate of a second modified example. [Figure 12] FIG. 10 is a bottom view showing a coil substrate of a second modified example. DETAILED DESCRIPTION OF THE INVENTION

[0026] [Embodiment] Fig. 1 is a top view showing a coil substrate 2 of the embodiment. Fig. 2 is a cross-sectional view taken along line II-II in Fig. 1 and Fig. 3. Fig. 3 is a bottom view showing the coil substrate 2 of the embodiment.

[0027] As shown in Figures 1 to 3, 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, terminal connection wiring 45U, 45V, 45W, coil-to-coil connection wiring 50U, 50V, 50W, and phase-to-phase connection wiring 60U, 60V, 60W.

[0028] 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 in a rectangular shape having four sides: a first side E1, a second side E2, a third side E3, and a fourth side E4. The first side E1 is a short side at one end of the flexible substrate 10 in the longitudinal direction (the direction of arrow LD in FIG. 1). The second side E2 is a short side at the other end of the flexible substrate 10 in the longitudinal direction. Both the first side E1 and the second side E2 are short sides extending in a direction perpendicular to the longitudinal direction of the flexible substrate 10 (the direction of arrow OD in FIG. 1). The third side E3 and the fourth side E4 are long sides extending in the longitudinal direction of the flexible substrate 10.

[0029] 1 and 3, the flexible substrate 10 has a first region R1 at one end in the longitudinal direction and a second region R2 adjacent to the first region R1. The first region R1 includes a first side E1, and the second region R2 includes a second side E2.

[0030] The U-phase terminal 40U, the V-phase terminal 40V, and the W-phase terminal 40W are formed on the third side E3 of the flexible substrate 10. In this 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. As shown in FIGS. 1 and 3 , the U-phase terminal 40U is connected to the starting end 20US of the U-phase coil 20U by a terminal connecting wiring 45U. The U-phase terminal 40U is also connected to the ending end 20WE of the W-phase coil 20W via an interphase connecting wiring 60W. The V-phase terminal 40V is connected to the starting end 20VS of the V-phase coil 20V by a terminal connecting wiring 45V. The V-phase terminal 40V is also connected to the ending end 20UE of the U-phase coil 20U via an interphase connecting wiring 60U. The W-phase terminal 40W is connected to the starting end 20WS of the W-phase coil 20W by a terminal connecting wiring 45W. Furthermore, W-phase terminal 40W is connected to termination 20VE of V-phase coil 20V via interphase connecting wiring 60V. That is, in the embodiment, U-phase coil 20U, V-phase coil 20V, and W-phase coil 20W are delta-connected. Note that, in other examples, U-phase coil 20U, V-phase coil 20V, and W-phase coil 20W may be Y-connected or may be connected in some other manner. Furthermore, the arrangement of U-phase terminal 40U, V-phase terminal 40V, and W-phase terminal 40W in a region is merely an example, and other arrangements are also possible.

[0031] Terminal connecting wiring 45U connects the coil wiring of U-phase coil 20U to U-phase terminal 40U, terminal connecting wiring 45V connects the coil wiring of V-phase coil 20V to V-phase terminal 40V, and terminal connecting wiring 45W connects the coil wiring of W-phase coil 20W to W-phase terminal 40W. Interphase connecting wiring 60U connects the coil wiring of U-phase coil 20U to V-phase terminal 40V, interphase connecting wiring 60V connects the coil wiring of V-phase coil 20V to W-phase terminal 40W, and interphase connecting wiring 60W connects the coil wiring of W-phase coil 20W to U-phase terminal 40U.

[0032] The U-phase coil 20U, the V-phase coil 20V, and the W-phase coil 20W respectively constitute the U-phase, the V-phase, and the W-phase of the three-phase motor.

[0033] As shown in FIGS. 1 and 3, a starting end 20US of U-phase coil 20U is disposed within first region R1. A terminal end 20UE of U-phase coil 20U is disposed within second region R2. U-phase coil 20U includes eight coils 31U, 32U, 33U, 34U, 35U, 36U, 37U, and 38U. Eight coils 31U to 38U are arranged in this order along the longitudinal direction of flexible substrate 10 from starting end 20US of U-phase coil 20U toward terminal end 20UE. Eight coils 31U to 38U are connected to each other by inter-coil connection wiring 50U.

[0034] Each of the eight coils 31U to 38U is formed such that a first coil wiring constituting half of one turn is formed on the first surface 10F side, and a second coil wiring constituting the remaining half turn is formed on the second surface 10B side, with adjacent turns being staggered. The first coil wiring and the second coil wiring are electrically connected by through holes or via holes formed in the flexible substrate 10.

[0035] The winding start positions (starting ends) of the first coil 31U, the third coil 33U, the fifth coil 35U, and the seventh coil 37U from the starting end 20US of the U-phase coil 20U are arranged on the first surface 10F, and the winding end positions (terminating ends) are arranged on the second surface 10B. When the flexible substrate 10 is viewed from the first surface 10F side, the coils 31U, 33U, 35U, and 37U are wound counterclockwise.

[0036] Meanwhile, the winding start positions (starting ends) of the second coil 32U, the fourth coil 34U, the sixth coil 36U, and the eighth coil 38U from the starting end 20US of the U-phase coil 20U are arranged on the second surface 10B, and the winding end positions (terminating ends) are arranged on the first surface 10F. When the flexible substrate 10 is viewed from the first surface 10F side, the coils 32U, 34U, 36U, and 38U are wound clockwise.

[0037] 1, 2, and 3, a portion of the wiring (second coil wiring) on ​​the second surface 10B side of the coil 31U overlaps a portion of the wiring (first coil wiring) on ​​the first surface 10F side of the adjacent coil 32U via the flexible substrate 10. Also, a portion of the wiring (second coil wiring) on ​​the second surface 10B side of the coil 32U overlaps a portion of the wiring (first coil wiring) on ​​the first surface 10F side of the adjacent coil 33U. Also, a portion of the wiring (second coil wiring) on ​​the second surface 10B side of the coil 33U overlaps a portion of the wiring (first coil wiring) on ​​the first surface 10F side of the adjacent coil 34U. Also, a portion of the wiring (second coil wiring) on ​​the second surface 10B side of the coil 34U overlaps a portion of the wiring (first coil wiring) on ​​the first surface 10F side of the adjacent coil 35U. Furthermore, a portion of the wiring (second coil wiring) on ​​the second surface 10B side of coil 35U overlaps a portion of the wiring (first coil wiring) on ​​the first surface 10F side of adjacent coil 36U. Further, a portion of the wiring (second coil wiring) on ​​the second surface 10B side of coil 36U overlaps a portion of the wiring (first coil wiring) on ​​the first surface 10F side of adjacent coil 37U. Further, a portion of the wiring (second coil wiring) on ​​the second surface 10B side of coil 37U overlaps a portion of the wiring (first coil wiring) on ​​the first surface 10F side of adjacent coil 38U.

[0038] 1 and 3, the coil-to-coil connection wiring 50U connecting coil 31U and coil 32U, the coil-to-coil connection wiring 50U connecting coil 33U and coil 34U, the coil-to-coil connection wiring 50U connecting coil 35U and coil 36U, and the coil-to-coil connection wiring 50U connecting coil 37U and coil 38U are arranged on the second surface 10B. On the other hand, the coil-to-coil connection wiring 50U connecting coil 32U and coil 33U, the coil-to-coil connection wiring 50U connecting coil 34U and coil 35U, and the coil-to-coil connection wiring 50U connecting coil 36U and coil 37U are arranged on the first surface 10F. The U-phase terminal 40U, terminal connection wiring 45U, and interphase connection wiring 60U are arranged on the first surface 10F.

[0039] As shown in FIGS. 1 and 3, a starting end 20VS of the V-phase coil 20V is disposed within the second region R2. A terminal end 20VE of the V-phase coil 20V is disposed within the first region R1. The V-phase coil 20V includes eight coils 31V, 32V, 33V, 34V, 35V, 36V, 37V, and 38V. The eight coils 31V to 38V are arranged in this order along the longitudinal direction of the flexible substrate 10 from the starting end 20VS of the V-phase coil 20V toward the terminal end 20VE. The eight coils 31V to 38V are connected to each other by inter-coil connection wiring 50V.

[0040] Each of the eight coils 31V to 38V is formed by forming a first coil wiring, which constitutes half of one turn, on the first surface 10F side, and a second coil wiring, which constitutes the remaining half turn, on the second surface 10B side, with adjacent turns being offset from one another. The first coil wiring and the second coil wiring are electrically connected by through holes or via holes formed in the flexible substrate 10.

[0041] The winding start positions (starting ends) of the first coil 31V, the third coil 33V, the fifth coil 35V, and the seventh coil 37V from the starting end 20VS of the V-phase coil 20V are arranged on the first surface 10F, and the winding end positions (terminating ends) are arranged on the second surface 10B. When the flexible substrate 10 is viewed from the first surface 10F side, the coils 31V, 33V, 35V, and 37V are wound counterclockwise.

[0042] Meanwhile, the winding start positions (starting ends) of the second coil 32V, the fourth coil 34V, the sixth coil 36V, and the eighth coil 38V from the starting end 20VS of the V-phase coil 20V are arranged on the second surface 10B, and the winding end positions (terminating ends) are arranged on the first surface 10F. When the flexible substrate 10 is viewed from the first surface 10F side, the coils 32V, 34V, 36V, and 38V are wound clockwise.

[0043] 1, 2, and 3, a portion of the wiring (first coil wiring) on ​​the first surface 10F side of the coil 31V overlaps a portion of the wiring (second coil wiring) on ​​the second surface 10B side of the adjacent coil 32V via the flexible substrate 10. Also, a portion of the wiring (first coil wiring) on ​​the first surface 10F side of the coil 32V overlaps a portion of the wiring (second coil wiring) on ​​the second surface 10B side of the adjacent coil 33V. Also, a portion of the wiring (first coil wiring) on ​​the first surface 10F side of the coil 33V overlaps a portion of the wiring (second coil wiring) on ​​the second surface 10B side of the adjacent coil 34V. Also, a portion of the wiring (first coil wiring) on ​​the first surface 10F side of the coil 34V overlaps a portion of the wiring (second coil wiring) on ​​the second surface 10B side of the adjacent coil 35V. Furthermore, a portion of the wiring (first coil wiring) on ​​the first surface 10F side of coil 35V overlaps a portion of the wiring (second coil wiring) on ​​the second surface 10B side of adjacent coil 36V. Further, a portion of the wiring (first coil wiring) on ​​the first surface 10F side of coil 36V overlaps a portion of the wiring (second coil wiring) on ​​the second surface 10B side of adjacent coil 37V. Further, a portion of the wiring (first coil wiring) on ​​the first surface 10F side of coil 37V overlaps a portion of the wiring (second coil wiring) on ​​the second surface 10B side of adjacent coil 38V.

[0044] 1 and 3, the coil-to-coil connection wiring 50V connecting coil 31V and coil 32V, the coil-to-coil connection wiring 50V connecting coil 33V and coil 34V, the coil-to-coil connection wiring 50V connecting coil 35V and coil 36V, and the coil-to-coil connection wiring 50V connecting coil 37V and coil 38V are arranged on the second surface 10B. On the other hand, the coil-to-coil connection wiring 50V connecting coil 32V and coil 33V, the coil-to-coil connection wiring 50V connecting coil 34V and coil 35V, and the coil-to-coil connection wiring 50V connecting coil 36V and coil 37V are arranged on the first surface 10F. The V-phase terminal 40V, the terminal connection wiring 45V, and the interphase connection wiring 60V are arranged on the first surface 10F.

[0045] As shown in FIGS. 1 and 3, a starting end 20WS of the W-phase coil 20W is disposed within the first region R1. A terminal end 20WE of the W-phase coil 20W is disposed within the second region R2. The W-phase coil 20W includes eight coils 31W, 32W, 33W, 34W, 35W, 36W, 37W, and 38W. The eight coils 31W to 38W are arranged in this order along the longitudinal direction of the flexible substrate 10 from the starting end 20WS of the W-phase coil 20W toward the terminal end 20WE. The eight coils 31W to 38W are connected to each other by inter-coil connection wiring 50W.

[0046] Each of the eight coils 31W to 38W is formed such that the first coil wiring, which constitutes half of one turn, is formed on the first surface 10F side, and the second coil wiring, which constitutes the remaining half turn, is formed on the second surface 10B side, with adjacent turns being offset from one another. The first coil wiring and the second coil wiring are electrically connected by through holes or via holes formed in the flexible substrate 10.

[0047] The winding start positions (starting ends) of the first coil 31W, the third coil 33W, the fifth coil 35W, and the seventh coil 37W from the starting end 20WS of the W-phase coil 20W are arranged on the first surface 10F, and the winding end positions (terminating ends) are arranged on the second surface 10B. When the flexible substrate 10 is viewed from the first surface 10F side, the coils 31W, 33W, 35W, and 37W are wound counterclockwise.

[0048] Meanwhile, the winding start positions (starting ends) of the second coil 32W, the fourth coil 34W, the sixth coil 36W, and the eighth coil 38W from the starting end 20WS of the W-phase coil 20W are arranged on the second surface 10B, and the winding end positions (terminating ends) are arranged on the first surface 10F. When the flexible substrate 10 is viewed from the first surface 10F side, the coils 32W, 34W, 36W, and 38W are wound clockwise.

[0049] 1, 2, and 3, a portion of the wiring (second coil wiring) on ​​the second surface 10B side of the coil 31W overlaps a portion of the wiring (first coil wiring) on ​​the first surface 10F side of the adjacent coil 32W via the flexible substrate 10. Also, a portion of the wiring (second coil wiring) on ​​the second surface 10B side of the coil 32W overlaps a portion of the wiring (first coil wiring) on ​​the first surface 10F side of the adjacent coil 33W. A portion of the wiring (second coil wiring) on ​​the second surface 10B side of the coil 33W overlaps a portion of the wiring (first coil wiring) on ​​the first surface 10F side of the adjacent coil 34W. A portion of the wiring (second coil wiring) on ​​the second surface 10B side of the coil 34W overlaps a portion of the wiring (first coil wiring) on ​​the first surface 10F side of the adjacent coil 35W. A portion of the wiring (second coil wiring) on ​​the second surface 10B side of coil 35W overlaps a portion of the wiring (first coil wiring) on ​​the first surface 10F side of adjacent coil 36W. A portion of the wiring (second coil wiring) on ​​the second surface 10B side of coil 36W overlaps a portion of the wiring (first coil wiring) on ​​the first surface 10F side of adjacent coil 37W. A portion of the wiring (second coil wiring) on ​​the second surface 10B side of coil 37W overlaps a portion of the wiring (first coil wiring) on ​​the first surface 10F side of adjacent coil 38W.

[0050] 1 and 3, the coil-to-coil connection wiring 50W connecting coil 31W and coil 32W, the coil-to-coil connection wiring 50W connecting coil 33W and coil 34W, the coil-to-coil connection wiring 50W connecting coil 35W and coil 36W, and the coil-to-coil connection wiring 50W connecting coil 37W and coil 38W are arranged on the second surface 10B. On the other hand, the coil-to-coil connection wiring 50W connecting coil 32W and coil 33W, the coil-to-coil connection wiring 50W connecting coil 34W and coil 35W, and the coil-to-coil connection wiring 50W connecting coil 36W and coil 37W are arranged on the first surface 10F. The W-phase terminal 40W, terminal connection wiring 45W, and interphase connection wiring 60W are arranged on the first surface 10F.

[0051] 1 and 3, interphase connecting wire 60W connects end 20WE of W-phase coil 20W to terminal connecting wire 45U. Interphase connecting wire 60W extends from second region R2 to first region R1.

[0052] As shown in FIGS. 1 and 3 , in this embodiment, the wiring of each of the coils 20U, 20V, and 20W is arranged in a hexagonal shape. In other examples, the wiring of each of the coils 20U, 20V, and 20W may be arranged in any shape, such as a circle (a perfect circle or an ellipse), a triangle, a quadrangle (a square, a rectangle, a diamond), a pentagon, or a polygon with more than two sides. The wiring arrangement of all the coils does not necessarily have to be the same; the wiring arrangement may differ between the coils. The number of turns of one coil wiring is not particularly limited, but may be one or more turns, preferably three to seven turns. The coil wiring is formed by forming a half turn of the first coil wiring on the first surface 10F and a half turn of the second coil wiring on the second surface 10B, and connecting the first coil wiring and the second coil wiring via a through hole or a via hole. A half turn refers to half of the coil wiring. Alternatively, a quarter turn may be formed on the first surface 10F and a quarter turn on the second surface 10B, and these may be connected by a through hole or a via hole, forming a half turn in total on the first surface 10F or the second surface 10B. Furthermore, the coil wiring may be disposed on either the first surface 10F or the second surface 10B. In this case, the coil wiring on the first surface 10F and the coil wiring on the second surface 10B may overlap entirely, partially, or not at all.

[0053] As shown in FIGS. 1 to 3, a first insulating layer 47F is formed on the first surface 10F of the flexible substrate 10, and a second insulating layer 47B is formed on the second surface 10B. In the third region R3, the first insulating layer 47F is not formed, but the second insulating layer 47B is formed. In the fourth region R4, both the first insulating layer 47F and the second insulating layer 47B are formed. In the fifth region R5, the first insulating layer 47F is formed, but the second insulating layer 47B is not formed. The insulating layers 47F and 47B can be formed, for example, by printing a liquid resin, or by using a coverlay. The resin of the insulating layer is, for example, polyimide.

[0054] The first insulating layer 47F covers the first surface 10F in the fourth region R4 and the fifth region R5 of the flexible substrate 10, the first coil wiring of each coil, and through holes or via holes. As shown in FIG. 2, the thickness of the first insulating layer 47F is greater than the thickness of the first coil wiring of each coil. As shown in FIG. 1, an end face 47Fa of the first insulating layer 47F on the third region R3 side is linear and substantially parallel to the second edge E2 of the flexible substrate 10. An end face 47Fb of the first insulating layer 47F on the first edge E1 side substantially coincides with the first edge E1 of the flexible substrate 10. The end face 47Fa may be formed in a concave shape so as to substantially conform to the arrangement of the first coil wiring of the coil 38W closest to the second edge E2.

[0055] The second insulating layer 47B covers the second surface 10B in the third region R3 and the fourth region R4 of the flexible substrate 10, the second coil wiring of each coil, and through-holes or via holes. As shown in FIG. 2, the thickness of the second insulating layer 47B is greater than the thickness of the second coil wiring of each coil. As shown in FIG. 3, an end face 47Ba of the second insulating layer 47B on the fifth region R5 side is linear and substantially parallel to the first edge E1 of the flexible substrate 10. An end face 47Bb of the second insulating layer 47B on the second edge E2 side substantially coincides with the second edge E2 of the flexible substrate 10. The end face 47Ba may be formed concavely to substantially conform to the arrangement of the second coil wiring of the coil 31U closest to the first edge E1. The formation of the first insulating layer 47F and the second insulating layer 47B is merely an example, and they may be formed over the entire surface of the flexible substrate 10, or other combinations may be used.

[0056] [Motor coil substrate] Fig. 4 is a side view of a motor coil substrate 550 using the coil substrate 2 (Figs. 1 to 3) of the embodiment, viewed from the central axis direction. Fig. 5 is a partially enlarged view of the vicinity of the imaginary line VL1 of the motor coil substrate 550 shown in Fig. 4. Fig. 6 is a partially enlarged view of the vicinity of the imaginary line VL2 of the motor coil substrate 550 shown in Fig. 4.

[0057] As shown in FIG. 4 , the coil substrate 2 of the embodiment is wound into a cylindrical shape around a cylindrical core (not shown) to form a motor coil substrate 550 for a motor. When the coil substrate 2 is wound into a cylindrical shape, the winding starts at the first side E1 of the flexible substrate 10 and ends at the second side E2 of the flexible substrate 10. The coil substrate 2 is wound multiple times in the circumferential direction around a central axis AX extending parallel to the first side E1, starting from the first side E1. The number of windings of the coil substrate 2 is preferably between 2 and 10. In this embodiment, the number of windings of the coil substrate 2 is approximately 2. When the coil substrate 2 is wound into a cylindrical shape, the first surface 10F of the flexible substrate 10 is disposed on the outer periphery, and the second surface 10B is disposed on the inner periphery. Note that when the coil substrate 2 is wound into a cylindrical shape, the first surface 10F of the flexible substrate 10 may be disposed on the inner periphery, and the second surface 10B may be disposed on the outer periphery.

[0058] The coil substrate 2 is wound such that the coils 31U, 32U, 33U, and 34U in the first region R1 and the coils 35U, 36U, 37U, and 38U in the second region R2 overlap each other in the radial direction. Similarly, the coil substrate 2 is wound such that the coils 38V, 37V, 36V, and 35V in the first region R1 and the coils 34V, 33V, 32V, and 31V in the second region R2 overlap each other in the radial direction. Similarly, the coil substrate 2 is wound such that the coils 31W, 32W, 33W, and 34W in the first region R1 and the coils 35W, 36W, 37W, and 38W in the second region R2 overlap each other in the radial direction. As a result, as shown in FIG. 4, the coil substrate 2 is wound such that the U phase, V phase, and W phase are repeated four times per revolution. The coil substrate 2 may be configured so that the U phase, V phase, and W phase are repeated 1 to 3 times, or 5 or more times in one turn.

[0059] As shown in FIG. 4, the winding start is defined at end face 47Fb on one longitudinal end (the side of first side E1) of first insulating layer 47F, and the winding end is defined at end face 47Fa on the other longitudinal end of first insulating layer 47F. A virtual line VL1 is defined on the cylindrical cross section of motor coil substrate 550, connecting the winding start (end face 47Fb) of first insulating layer 47F with central axis AX, which is the center of the cylinder of coil substrate 2. Coil substrate 2 is wound so that the winding end (end face 47Fa) of first insulating layer 47F does not extend beyond virtual line VL1. The circumferential distance d1 between virtual line VL1 and the winding end (end face 47Fa) of first insulating layer 47F is greater than 0 and is equal to or less than the circumferential length D1 of any one of the U-, V-, and W-phase coils located in the innermost layer when wound in a substantially cylindrical shape. In the example shown in FIG. 4, length D1 is the circumferential length of the portion of the innermost first insulating layer 47F that corresponds to the U phase, and the circumferential length is in an angular range of 30°.

[0060] Furthermore, the winding start is defined at end face 47Ba on one longitudinal end of second insulating layer 47B, and the winding end is defined at end face 47Bb on the other longitudinal end (the side of second side E2) of second insulating layer 47B. A virtual line VL2 is a straight line connecting the winding start (end face 47Ba) of second insulating layer 47B and central axis AX, which is the center of the cylinder of coil substrate 2, and is provided on the cylindrical cross section of motor coil substrate 550. Coil substrate 2 is wound so that the winding end (end face 47Bb) of second insulating layer 47B does not extend beyond virtual line VL2. The circumferential distance d2 between virtual line VL2 and the winding end (end face 47Bb) of second insulating layer 47B is greater than 0 and is equal to or less than the circumferential length D2 of any one of the U-, V-, and W-phase coils located in the innermost layer when wound approximately cylindrically. In the example shown in FIG. 4, length D2 is the circumferential length of the portion of the innermost second insulating layer 47B that corresponds to the U phase, and the circumferential length is in an angular range of 30°.

[0061] As shown in FIG. 4, in the innermost layer, the angular range of approximately 90° clockwise from the imaginary line VL1 corresponds to the fifth region R5 described above, where the second insulating layer 47B is not formed. In this angular range, the coil substrate 2, which is made up of the flexible substrate 10 and the first insulating layer 47F, is wound along the outer periphery CM of the core material. At the imaginary line VL2, which is approximately 90° clockwise from the imaginary line VL1, the coil substrate 2 is wound so as to climb over the end face 47Ba of the second insulating layer 47B, resulting in a protruding shape on the outer periphery due to a step. The angular range from the imaginary line VL2 to the position (imaginary line VL1) at approximately 360°, which is the end of the first turn, corresponds to the fourth region R4 described above, where both the first insulating layer 47F and the second insulating layer 47B are formed. In this angular range, the coil substrate 2, which is made up of the second insulating layer 47B, the flexible substrate 10, and the first insulating layer 47F, is wound along the outer periphery CM of the core material. At the imaginary line VL1 where the first turn ends, the coil substrate 2 is wound so as to climb over the end face 47Fb of the first insulating layer 47F and the first side E1 of the flexible substrate 10, so that a protrusion is formed on the outer periphery due to a step.

[0062] In the second turn, the angle range of approximately 90° clockwise from the imaginary line VL1 corresponds to the fourth region R4 described above, and the coil substrate 2, which is made up of the second insulating layer 47B, the flexible substrate 10, and the first insulating layer 47F, is wound along the outer periphery of the innermost coil substrate 2. At the imaginary line VL2 of the second turn, the coil substrate 2 is wound so as to go beyond the protruding shape of the inner coil substrate 2, resulting in a protruding shape on the outer periphery. The angle range from the imaginary line VL2 to the approximately 360° position (imaginary line VL1), which is the end of the second turn, corresponds to the fourth region R4 described above, and the coil substrate 2, which is made up of the second insulating layer 47B, the flexible substrate 10, and the first insulating layer 47F, is wound along the outer periphery of the innermost coil substrate 2. At the imaginary line VL1, which is the end of the second turn, the coil substrate 2 is wound so as to go beyond the protruding shape of the innermost coil substrate 2, resulting in a protruding shape on the outer periphery. At this time, the first insulating layer 47F of the coil substrate 2 is wound so as not to exceed the imaginary line VL1, specifically so that a gap of distance d1 is formed between the end face 47Fa and the imaginary line VL1. This prevents the cross-sectional shape of the motor coil substrate 550 from having a pronounced protrusion at the imaginary line VL1, compared to when the first insulating layer 47F is wound beyond the imaginary line VL1. As a result, the cross-sectional shape of the motor coil substrate 550 can be made substantially circular.

[0063] In the third turn, the angular range of approximately 90° clockwise from the imaginary line VL1 corresponds to the aforementioned third region R3, where the first insulating layer 47F is not formed. In this angular range, the coil substrate 2, which is made up of the flexible substrate 10 and the second insulating layer 47B, is wound along the outer periphery of the inner coil substrate 2. In the third turn, the flexible substrate 10 and the second insulating layer 47B are wound so as not to exceed the imaginary line VL2; specifically, so that a gap of distance d2 is formed between the end face 47Bb and the imaginary line VL2. This prevents the cross-sectional shape of the motor coil substrate 550 from having a pronounced protrusion at the imaginary line VL2, compared to when the second insulating layer 47B is wound beyond the imaginary line VL2. As a result, the cross-sectional shape of the motor coil substrate 550 can be made approximately circular.

[0064] Making the cross-sectional shape of the motor coil substrate 550 nearly perfect circular or perfect circular means making the cylindricity of the outer peripheral surface of the motor coil substrate 550 greater than 0.0 mm and equal to or less than 0.3 mm. The cylindricity of the outer peripheral surface is measured using a V-block 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 five different points. The average value is calculated to measure the cylindricity of the outer peripheral surface OC.

[0065] As shown in FIG. 5 , in the U-phase range to the right of the imaginary line VL1, the first coil wiring of coil 31U, the second coil wiring of coil 34U, the first coil wiring of coil 35U, and the second coil wiring of coil 38U overlap radially from the inner periphery to the outer periphery. Because the circumferential length of the outer periphery is longer than the circumferential length of the inner periphery within the same angular range, the wiring width W2 of coil 38U on the outer periphery is greater than the wiring width W3 of coil 31U on the inner periphery. In the V-phase range to the right of the imaginary line VL1, the first coil wiring of coil 38V, the second coil wiring of coil 35V, the first coil wiring of coil 34V, and the second coil wiring of coil 31V overlap radially from the inner periphery to the outer periphery. Therefore, the wiring width W2 of coil 31V on the outer periphery is greater than the wiring width W3 of coil 38V on the inner periphery. Similarly, in the V-phase range on the left side of the imaginary line VL1, the second coil wiring of coil 36V, the first coil wiring of coil 35V, the second coil wiring of coil 32V, and the first coil wiring of coil 31V overlap in the radial direction from the inner periphery to the outer periphery. For this reason, the wiring width W2 of coil 31V on the outer periphery side is greater than the wiring width W3 of coil 36V on the inner periphery side.

[0066] In the range of the W phase on the left side of the virtual line VL1, from the inner peripheral side to the outer peripheral side, the second coil wiring of the coil 33W, the first coil wiring of the coil 34W, the second coil wiring of the coil 37W, and the first coil wiring of the coil 38W overlap in the radial direction respectively. Here, the wiring width W1 of the coil 38W on the outer peripheral side is smaller than the wiring width W2 of the adjacent coil 31V. That is, among the plurality of coils of the coil substrate 2, the wiring width W1 of the coil 38W (an example of the first coil wiring) located in the outermost layer in a substantially cylindrical wound state and closest to the end of the winding of the first insulating layer 47F, and the wiring width W2 of the coil 31V (an example of the second coil wiring) adjacent to the coil 38W in the outermost layer satisfy the relationship of Equation 1. W1 < W2 ···· (Equation 1) Also, the wiring width W1 of the coil 38W and the wiring width W2 of the coil 31V satisfy the relationship of Equation 2. 1 / 2 ≦ W1 / W2 < 1 ···· (Equation 2) Furthermore, the wiring width W1 of the coil 38W and the wiring width W3 of the coils 31U and 38V (an example of the third coil wiring) located in the innermost layer in a substantially cylindrical wound state among the plurality of coils of the coil substrate 2 satisfy the relationship of Equation 3. W1 = W3 ···· (Equation 3) Note that the wiring width W1 of the coil 38W does not have to be the same as the wiring width W3 as long as it satisfies the relationship of Equation 2.

[0067] As described above, by making the wiring width W1 of the coil 38W smaller than the wiring width W2 of the coil 31V, the length of the vicinity of the end of the winding of the first insulating layer 47F can be shortened. As a result, when the coil substrate 2 is wound into a cylindrical shape, the end face 47Fa of the end of the winding of the first insulating layer 47F can be made not to exceed the virtual line VL1.

[0068] As shown in FIG. 6, in the range of the U phase on the right side of the virtual line VL2, from the inner peripheral side to the outer peripheral side, the second coil wiring of the coil 31U, the first coil wiring of the coil 32U, the second coil wiring of the coil 35U, and the first coil wiring of the coil 36U radially overlap each other. Since the peripheral length on the outer peripheral side is longer than the peripheral length on the inner peripheral side in the same angular range, the wiring width W2 of the coil 36U on the outer peripheral side is larger than the wiring width W3 of the coil 31U on the inner peripheral side. In the range of the V phase on the right side of the virtual line VL2, from the inner peripheral side to the outer peripheral side, the second coil wiring of the coil 38V, the first coil wiring of the coil 37V, the second coil wiring of the coil 34V, and the first coil wiring of the coil 33V radially overlap each other. Therefore, the wiring width W2 of the coil 33V on the outer peripheral side is larger than the wiring width W3 of the coil 38V on the inner peripheral side. Similarly, in the range of the V phase on the left side of the virtual line VL2, from the inner peripheral side to the outer peripheral side, the first coil wiring of the coil 38V, the second coil wiring of the coil 35V, the first coil wiring of the coil 34V, and the second coil wiring of the coil 31V radially overlap each other. Therefore, the wiring width W2 of the coil 31V on the outer peripheral side is larger than the wiring width W3 of the coil 38V on the inner peripheral side.

[0069] In the range of the W phase on the left side of the virtual line VL2, from the inner peripheral side to the outer peripheral side, the first coil wiring of the coil 31W, the second coil wiring of the coil 34W, the first coil wiring of the coil 35W, and the second coil wiring of the coil 38W radially overlap each other. Here, the wiring width W1 of the coil 38W on the outer peripheral side is smaller than the wiring width W2 of the adjacent coil 31V. That is, among the plurality of coils included in the coil substrate 2, the wiring width W1 of the coil 38W (an example of the first coil wiring) located on the outermost layer in the state of being wound in a substantially cylindrical shape and closest to the end of winding of the second insulating layer 47B, and the wiring width W2 of the coil 31V (an example of the second coil wiring) adjacent to the coil 38W on the outermost layer satisfy the relationship of Equation 1. W1 < W2 ···· (Equation 1) Further, the wiring width W1 of the coil 38W and the wiring width W2 of the coil 31V satisfy the relationship of Equation 2. 1 / 2 ≦ W1 / W2 < 1 ···· (Equation 2) Furthermore, the wiring width W1 of coil 38W and the wiring width W3 of coils 31U, 38V (an example of third coil wiring) that are located in the innermost layer of the multiple coils on coil substrate 2 when wound in an approximately cylindrical shape satisfy the relationship of formula 3. W1=W3...(Formula 3) The wiring width W1 of the coil 38W does not have to be the same as the wiring width W3 as long as it satisfies the relationship of the above formula 2. The wiring widths W1, W2, and W3 of the coil are not particularly limited, but are preferably 50-600 μm. The thickness of the coil wiring is not particularly limited, but is preferably 20-200 μm.

[0070] As described above, by making the wiring width W1 of the coil 38W smaller than the wiring width W2 of the coil 31V, the length of the portion of the second insulating layer 47B near the winding end can be shortened. As a result, when the coil substrate 2 is wound into a cylindrical shape, the end surface 47Bb of the winding end of the second insulating layer 47B can be prevented from exceeding the imaginary line VL2. As an example in this embodiment, the wiring width W1 of the first coil wiring is 480 μm, the wiring width W2 of the second coil wiring is 570 μm, and the wiring width W3 of the third coil wiring is 480 μm.

[0071] [Motor] FIG. 7 is a cross-sectional view schematically showing a motor 600 using the motor coil substrate 550 (FIGS. 4 to 6) of the embodiment. The motor 600 is formed by providing one of the motor coil substrate 550 and the magnet 570 on a rotor 610 and providing the other on a stator 620. As shown in FIG. 7, the motor 600 is formed by placing the motor coil substrate 550 inside a yoke 560, and placing a rotating shaft 580 and a magnet 570 fixed to the rotating shaft 580 inside the motor coil substrate 550. The motor 600 of the embodiment is a slotless motor. The magnet 570 and the rotating shaft 580 form the rotor 610, and the motor coil substrate 550 and the yoke 560 form the stator 620.

[0072] Motor coil substrate 550 is disposed inside cylindrical yoke 560 (an example of a housing). An outer peripheral surface OC of motor coil substrate 550 and an inner peripheral surface 560a of yoke 560 are fixed by adhesive. An inner peripheral surface IC of motor coil substrate 550 and an outer peripheral surface 570a of magnet 570 are disposed so as to face each other in the radial direction with a predetermined gap therebetween.

[0073] In the embodiment, the magnet 570 is provided on the rotor 610, and the motor coil substrate 550 is provided on the stator 620, but this is not limiting. In another example, the magnet 570 may be provided on the stator, and the motor coil substrate 550 may be provided on the rotor. Furthermore, although the motor coil substrate 550 in the embodiment is used in a slotless motor, it may also be used in motors other than slotless motors.

[0074] [Effects of the embodiment] The configurations of the coil substrate 2 (FIGS. 1 to 3), motor coil substrate 550 (FIGS. 4 to 6), and motor 600 (FIG. 7) of the embodiment have been described above. As described above, the coil substrate 2 of the embodiment is wound into a substantially cylindrical shape to form the motor coil substrate 550. By making the wiring width W1 of the coil 38W located in the outermost layer and closest to the winding end of the first insulating layer 47F smaller than the wiring width W2 of the coil 31V adjacent to the coil 38W in the outermost layer, the length of the portion of the coil substrate 2 near the winding end of the first insulating layer 47F can be shortened. Similarly, by making the wiring width W1 of the coil 38W located in the outermost layer and closest to the winding end of the second insulating layer 47B smaller than the wiring width W2 of the coil 31V adjacent to the coil 38W in the outermost layer, the length of the portion of the coil substrate 2 near the winding end of the second insulating layer 47B can be shortened. As a result, the coil substrate 2 can be wound into a substantially cylindrical shape so that the winding end of the first insulating layer 47F does not exceed the imaginary line VL1, and the winding end of the second insulating layer 47B does not exceed the imaginary line VL2, thereby making it possible to form the motor coil substrate 550 into a perfect circular cross section. When the motor coil substrate 550 having a perfect circular shape is placed in the yoke 560 of the motor 600, the gap between the yoke 560 and the motor coil substrate 550 becomes uniform. By making the gap uniform, heat is less likely to be trapped even when the motor is operating, and a decrease in motor performance is suppressed.

[0075] In the coil substrate 2 of this embodiment, by setting the wiring width W1 of the coil 38W and the wiring width W2 of the coil 31V such that W1 / W2<1, the winding ends of the insulating layers 47F and 47B do not overlap with the imaginary lines VL1 and VL2. Furthermore, by setting W1 / W2 to 1 / 2≦W1 / W2, the wiring width W1 of the coil 38W, which is located on the outermost layer and closest to the winding end, does not become too small. This prevents an increase in wiring resistance and a decrease in current due to an excessively small wiring width, ensuring motor performance.

[0076] In the coil substrate 2 of the embodiment, when the motor coil substrate 550 is formed by winding the coil substrate 2 in a substantially cylindrical shape, coils of the same phase are arranged to overlap radially, so the wiring width of the coils increases toward the outer layers. In the embodiment, the wiring width W1 of the coil 38W located in the outermost layer and closest to the winding end is set equal to the wiring width W3 of the coil 31U located in the innermost layer. This ensures that the wiring width W1 of the coil 38W is smaller than the wiring width W2 of the adjacent coil 31V. Furthermore, since the wiring width W1 is set equal to the wiring width W3 of the coil 31U in the innermost layer, the design of the coil wiring and the manufacturing of the coil substrate are facilitated.

[0077] In the coil substrate 2 of the embodiment, the first insulating layer 47F is formed on the first surface 10F of the flexible substrate 10, and is wound into a substantially cylindrical shape to form the motor coil substrate 550. When the coil substrate 2 is wound into a substantially cylindrical shape to form the motor coil substrate 550, the winding is performed so that the end of the winding of the first insulating layer 47F does not exceed the imaginary line VL1, which is a straight line connecting the start of the winding of the first insulating layer 47F and the cylindrical central axis AX of the coil substrate 2, thereby making it possible to form the cross-sectional shape of the motor coil substrate 550 into a perfect circle. Similarly, in the coil substrate 2, the second insulating layer 47B is formed on the second surface 10B of the flexible substrate 10. When the coil substrate 2 is wound into a substantially cylindrical shape to form the motor coil substrate 550, the winding is performed so that the end of the second insulating layer 47B does not extend beyond the imaginary line VL2, which is a straight line connecting the start of the winding of the second insulating layer 47B and the cylindrical central axis AX of the coil substrate 2. This allows the cross-sectional shape of the motor coil substrate 550 to be a perfect circle. As a result, when the motor coil substrate 550, which has now become a perfect circle, is placed in the yoke 560 of the motor 600, the gap between the yoke 560 and the motor coil substrate 550 becomes uniform. By making the gap uniform, heat is less likely to build up even when the motor is operating, and a decrease in motor performance is suppressed.

[0078] In the coil substrate 2 of this embodiment, by making the circumferential distance d1 between the imaginary line VL1 and the winding end of the first insulating layer 47F greater than zero, the winding end of the first insulating layer 47F does not overlap with the imaginary line VL1. Similarly, by making the circumferential distance d2 between the imaginary line VL2 and the winding end of the second insulating layer 47B greater than zero, the winding end of the second insulating layer 47B does not overlap with the imaginary line VL2. Furthermore, by making the circumferential distance d1 between the imaginary line VL1 and the winding end of the first insulating layer 47F equal to or less than the circumferential length D1 of the portion of the innermost first insulating layer 47F corresponding to the U-phase, the wiring width W1 of the coil 38W located closest to the winding end on the outermost layer does not become too small. This prevents an increase in wiring resistance and a decrease in current due to an excessively small wiring width, thereby ensuring motor performance. Similarly, by setting the circumferential distance d2 between the imaginary line VL2 and the winding end of the second insulating layer 47B to be equal to or less than the circumferential length D2 of the portion of the innermost second insulating layer 47B that corresponds to the U-phase, the wiring width W1 of the coil 38W that is located closest to the winding end on the outermost layer does not become too small. This prevents an increase in wiring resistance and a decrease in current caused by an excessively small wiring width, ensuring motor performance.

[0079] In the coil substrate 2 of the embodiment, each coil is formed by electrically connecting a half turn of the first coil wiring on the first surface 10F of the flexible substrate 10 and a half turn of the second coil wiring on the second surface 10B via a through hole or a via hole. A motor coil substrate 550 having a perfectly circular cross section can be formed by using a coil substrate 2 having half-turn coil wiring formed on each of the first surface 10F and the second surface 10B.

[0080] The motor coil substrate 550 of the embodiment can have a cross-sectional shape that is a perfect circle. When the motor coil substrate 550 having a perfect circle shape is housed in the yoke 560 of the motor 600, the gap between the yoke 560 and the motor coil substrate 550 becomes uniform, thereby improving the motor performance.

[0081] The motor 600 of this embodiment is formed using a motor coil substrate 550 that has a perfect circular shape, thereby providing a high-performance motor.

[0082] [Modification of the embodiment] 8 to 10 show a first modified example of the embodiment. Fig. 8 is a cross-sectional view of the coil substrate 2 of the first modified example, taken along line II-II shown in Figs. 1 and 3. Fig. 9 is a side view of a motor coil substrate 550 using the coil substrate 2 of the first modified example, viewed from the central axis direction. Fig. 10 is a partially enlarged view of the vicinity of the imaginary line VL of the motor coil substrate 550 shown in Fig. 9.

[0083] 8 , in the first modified example, a first insulating layer 47F is formed over the entire first surface 10F of the flexible substrate 10, and a second insulating layer 47B is formed over the entire second surface 10B. That is, an end face 47Fb of the first insulating layer 47F on the first side E1 side substantially coincides with the first side E1 of the flexible substrate 10, and an end face 47Fa of the first insulating layer 47F on the second side E2 side substantially coincides with the second side E2 of the flexible substrate 10. Similarly, an end face 47Bb of the second insulating layer 47B on the second side E2 side substantially coincides with the second side E2 of the flexible substrate 10, and an end face 47Ba of the second insulating layer 47B on the first side E1 side substantially coincides with the first side E1 of the flexible substrate 10.

[0084] As shown in FIG. 9, the coil substrate 2 of the first modified example is wound cylindrically to form a motor coil substrate 550. The winding starts at a first edge E1 at one end of the flexible substrate 10 in the longitudinal direction, and ends at a second edge E2 at the other end of the flexible substrate 10 in the longitudinal direction. The coil substrate 2 is wound multiple times circumferentially around a central axis AX extending parallel to the first edge E1, starting from the first edge E1. In the first modified example, the number of windings of the coil substrate 2 is set to approximately two, as in the embodiment. As shown in FIG. 9, an imaginary line VL, which is a straight line connecting the first edge E1 at the winding start and the cylindrical central axis AX of the coil substrate 2, is provided on the cylindrical cross section of the motor coil substrate 550. The coil substrate 2 is wound so that the second edge E2 at the winding end does not exceed the imaginary line VL. The circumferential distance d between the imaginary line VL and the second edge E2 at the winding end is greater than 0 and is equal to or less than the circumferential length D of any one of the U-phase, V-phase, and W-phase coils located in the innermost layer when wound in a substantially cylindrical shape. In the example shown in Fig. 9, the length D is the circumferential length of the portion (within an angle range of 30°) of the innermost flexible substrate 10 that corresponds to the U-phase.

[0085] As shown in FIG. 9 , in the innermost layer, within an angular range of approximately 360° clockwise from the imaginary line VL, the coil substrate 2, which is composed of the second insulating layer 47B, the flexible substrate 10, and the first insulating layer 47F, is wound along the outer periphery CM of the core material. At the imaginary line VL, which marks the end of the first turn, the coil substrate 2 is wound so as to go over the end surface 47Fb of the first insulating layer 47F, the first edge E1 of the flexible substrate 10, and the end surface 47Ba of the second insulating layer 47B of the inner coil substrate 2, resulting in a protruding shape on the outer periphery due to the step. In the second turn, within an angular range of approximately 360° clockwise from the imaginary line VL, the coil substrate 2 is wound along the outer periphery of the innermost coil substrate 2. At the imaginary line VL, which marks the end of the second turn, the coil substrate 2 is wound so as not to go over the imaginary line VL; specifically, so that a gap of distance d is formed between the second edge E2 of the winding end and the imaginary line VL. This makes it possible to prevent the cross-sectional shape of the motor coil substrate 550 from having a pronounced protrusion at the imaginary line VL compared to when the second side E2 is wound beyond the imaginary line VL, and as a result, the cross-sectional shape of the motor coil substrate 550 can be made substantially circular.

[0086] As shown in FIG. 10, in the range of the U phase on the right side of the virtual line VL, from the inner peripheral side to the outer peripheral side, the first coil wiring of the coil 31U, the second coil wiring of the coil 34U, and the first coil wiring of the coil 35U radially overlap each other. Since the circumferential length on the outer peripheral side is longer than the circumferential length on the inner peripheral side in the same angular range, the wiring width W2 of the coil 35U on the outer peripheral side is larger than the wiring width W3 of the coil 31U on the inner peripheral side. In the range of the V phase on the right side of the virtual line VL, from the inner peripheral side to the outer peripheral side, the first coil wiring of the coil 38V, the second coil wiring of the coil 35V, and the first coil wiring of the coil 34V radially overlap each other. For this reason, the wiring width W2 of the coil 34V on the outer peripheral side is larger than the wiring width W3 of the coil 38V on the inner peripheral side. Similarly, in the range of the V phase on the left side of the virtual line VL, from the inner peripheral side to the outer peripheral side, the second coil wiring of the coil 36V, the first coil wiring of the coil 35V, and the second coil wiring of the coil 31V radially overlap each other. For this reason, the wiring width W2 of the coil 31V on the outer peripheral side is larger than the wiring width W3 of the coil 36V on the inner peripheral side.

[0087] In the range of the W phase on the left side of the virtual line VL, from the inner peripheral side to the outer peripheral side, the second coil wiring of the coil 33W, the first coil wiring of the coil 34W, and the second coil wiring of the coil 38W radially overlap each other. Here, the wiring width W1 of the coil 38W on the outer peripheral side is smaller than the wiring width W2 of the adjacent coil 31V. That is, among the plurality of coils of the coil substrate 2, the wiring width W1 of the coil 38W (an example of the first coil wiring) located on the outermost layer in a substantially cylindrical wound state and closest to the end of winding of the coil substrate 2, and the wiring width W2 of the coil 31V (an example of the second coil wiring) adjacent to the coil 38W on the outermost layer satisfy the relationship of Equation 1. W1 < W2 ···· (Equation 1) Also, the wiring width W1 of the coil 38W and the wiring width W2 of the coil 31V satisfy the relationship of Equation 2. 1 / 2 ≦ W1 / W2 < 1 ···· (Equation 2) Furthermore, the wiring width W1 of coil 38W and the wiring width W3 of coils 31U, 38V (an example of third coil wiring) that are located in the innermost layer of the multiple coils on coil substrate 2 when wound in an approximately cylindrical shape satisfy the relationship of formula 3. W1=W3...(Formula 3) The wiring width W1 of the coil 38W does not have to be the same as the wiring width W3 as long as the relationship of the above formula 2 is satisfied.

[0088] As described above, by making the wiring width W1 of coil 38W smaller than the wiring width W2 of coil 31V, it is possible to shorten the length of the portion of coil substrate 2 near the winding end. As a result, when coil substrate 2 is wound into a cylindrical shape, it is possible to prevent second edge E2 of the winding end from exceeding imaginary line VL. As an example of a modified example of the embodiment, the wiring width W1 of the first coil wiring is 480 μm, the wiring width W2 of the second coil wiring is 570 μm, and the wiring width W3 of the third coil wiring is 480 μm.

[0089] As described above, the coil substrate 2 of the first modified example is wound into a substantially cylindrical shape to form the motor coil substrate 550. At this time, the coil substrate 2 is wound into a substantially cylindrical shape so that the second side E2 at the end of the winding does not extend beyond the imaginary line VL, which is a straight line connecting the first side E1 at the start of the winding and the cylindrical central axis AX of the coil substrate 2, and therefore the cross section of the motor coil substrate 550 can be made into a perfect circle. As a result, when the motor coil substrate 550 having a perfect circle shape is accommodated in the yoke 560 of the motor 600, the gap between the yoke 560 and the motor coil substrate 550 becomes uniform, thereby improving motor performance.

[0090] 11 and 12 show a second modified example of the embodiment. Fig. 11 is a top view showing a coil substrate 102 of the second modified example. Fig. 12 is a bottom view showing the coil substrate 102 of the second modified example.

[0091] 11 and 12 , coil substrate 102 includes flexible substrate 10, U-phase coil 20U, V-phase coil 20V, W-phase coil 20W, U-phase terminal 40U, V-phase terminal 40V, W-phase terminal 40W, terminal connecting wires 45U, 45V, 45W, and inter-phase connecting wires 60U, 60V, 60W. In the second modified example, coils 31U, 31V, 31W constituting U-phase coil 20U, V-phase coil 20V, and W-phase coil 20W form a spiral with first coil wiring on first surface 10F and form a spiral with second coil wiring on second surface 10B, and the first coil wiring and second coil wiring are connected by through holes TH or via holes VH. In addition, in Figures 11 and 12, only coils 31U, 31V, and 31W are shown as the coils that make up U-phase coil 20U, V-phase coil 20V, and W-phase coil 20W, but U-phase coil 20U, V-phase coil 20V, and W-phase coil 20W may be formed by multiple coils including coils 31U, 31V, and 31W.

[0092] 11 and 12, U-phase terminal 40U, V-phase terminal 40V, W-phase terminal 40W, terminal connecting wires 45U, 45V, 45W, first coil wiring of coils 31U, 31V, 31W, and a portion of interphase connecting wire 60W on the terminal connecting wire 45U side are formed on a first surface 10F of flexible substrate 10. On the other hand, interphase connecting wires 60U, 60V, second coil wiring of coils 31U, 31V, 31W, and a portion of interphase connecting wire 60W on the coil 31W side are formed on a second surface 10B of flexible substrate 10.

[0093] The first coil wiring on the first surface 10F constituting the coil 31U and the second coil wiring on the second surface 10B constituting the coil 31U are each formed in a spiral shape (a hexagonal spiral shape). The first coil wiring and the second coil wiring are overlapped via the flexible substrate 10, and the inner peripheral end of the first coil wiring and the inner peripheral end of the second coil wiring are connected via a through hole TH or a via hole VH. As shown in FIG. 11, the outer peripheral end of the first coil wiring of the coil 31U is connected to the U-phase terminal 40U via a terminal connection wiring 45U. As shown in FIG. 12, the outer peripheral end of the second coil wiring of the coil 31U is connected to one end of the interphase connection wiring 60U.

[0094] The first coil wiring on the first surface 10F constituting the coil 31V and the second coil wiring on the second surface 10B constituting the coil 31V are each formed in a spiral shape (a hexagonal spiral shape). The first coil wiring and the second coil wiring are overlapped via the flexible substrate 10, and the inner peripheral end of the first coil wiring and the inner peripheral end of the second coil wiring are connected via a through hole TH or a via hole VH. As shown in FIG. 11, the outer peripheral end of the first coil wiring of the coil 31V is connected to the V-phase terminal 40V via the terminal connection wiring 45V and to the other end of the interphase connecting wiring 60U via a through hole TH or a via hole VH. As shown in FIG. 12, the outer peripheral end of the second coil wiring of the coil 31V is connected to one end of the interphase connecting wiring 60V.

[0095] The first coil wiring on the first surface 10F constituting the coil 31W and the second coil wiring on the second surface 10B constituting the coil 31W are each formed in a spiral shape (a hexagonal spiral shape). The first coil wiring and the second coil wiring are overlapped via the flexible substrate 10, and the inner peripheral end of the first coil wiring and the inner peripheral end of the second coil wiring are connected via through-holes TH or via-holes VH. As shown in FIG. 11, the outer peripheral end of the first coil wiring of the coil 31W is connected to the W-phase terminal 40W via the terminal connection wiring 45W and to the other end of the interphase connection wiring 60V via the through-holes TH or via-holes VH. As shown in FIG. 12, the outer peripheral end of the second coil wiring of the coil 31W is connected to one end of the interphase connection wiring 60W. The portion of the interphase connection wiring 60W on the coil 31W side and the portion on the terminal connection wiring 45U side are connected via the through-holes TH or via-holes VH.

[0096] 11 and 12, in the second modified example, the wiring of each of coils 20U, 20V, and 20W is arranged in a hexagonal shape. In other examples, the wiring of each of coils 20U, 20V, and 20W may be arranged in any shape, such as a circle (a perfect circle, an ellipse), a triangle, a quadrangle (a square, a rectangle, a diamond), a pentagon, or a polygon with seven or more sides. Furthermore, the wiring arrangement shape of all coils does not have to be the same, and the wiring arrangement shape may differ between coils.

[0097] The coil substrate 102 of the second modified example also has the same characteristics as the coil substrate 2 of the embodiment. That is, when the coil substrate 102 is wound into a substantially cylindrical shape to form the motor coil substrate 550, the coil substrate 102 is wound into a substantially cylindrical shape so that the second edge E2 at the end of the winding does not extend beyond the imaginary line VL, which is a straight line connecting the first edge E1 at the start of the winding and the cylindrical central axis AX of the coil substrate 102. This allows the cross-sectional shape of the motor coil substrate 550 to be a perfect circle. As a result, when the motor coil substrate 550 having a perfect circle shape is accommodated in the yoke 560 of the motor 600, the gap between the yoke 560 and the motor coil substrate 550 becomes uniform, thereby improving motor performance.

[0098] In the coil substrate 102 of the second modified example, a coil is formed by electrically connecting the spiral of the first coil wiring on the first surface 10F and the spiral of the second coil wiring on the second surface 10B via a through hole or a via hole. A motor coil substrate 550 having a perfectly circular cross section can be formed by using a coil substrate 102 having spiral coil wiring formed on the first surface 10F or the second surface 10B. [Explanation of symbols]

[0099] 2 Coil board 10 Flexible substrate (resin substrate) 10B 2nd side 10F 1st page 20U U-phase coil (coil wiring) 20V V-phase coil (coil wiring) 20W W-phase coil (coil wiring) 40U U phase terminal 40V V phase terminal 40W W phase terminal 47F First insulating layer 47Fa end face 47Fb end face 47B Second insulating layer 47Ba end face 47Bb end face 102 Coil board 550 Motor coil board 570 Magnet 600 motor 610 Rotor 620 Stator AX center axis D Length D1 length D2 length d distance d1 distance d2 distance E1 First side E2 Second edge VL Virtual Line VL1 Virtual Line VL2 Virtual Line W1 Wiring width W2 Wiring width W3 Wiring width

Claims

1. A coil substrate having a resin substrate having a first surface and a second surface opposite to the first surface, and a plurality of coil wires arranged along a longitudinal direction of the resin substrate, the coil substrate being wound into a substantially cylindrical shape to form a motor coil substrate, a first side on one end side in the longitudinal direction of the resin substrate is a winding start point, a second side on the other end side in the longitudinal direction of the resin substrate is a winding end point, and the resin substrate is wound a plurality of times in the circumferential direction around an axis extending parallel to the first side, with the winding start point as a starting point, Among the plurality of coil wirings, there is a first coil wiring that is located in the outermost layer in the substantially cylindrically wound state and that is located closest to the winding end, and a second coil wiring that is adjacent to the first coil wiring in the outermost layer, A wiring width W1 of the first coil wiring and a wiring width W2 of the second coil wiring satisfy the relationship of Equation 1. W1<W2...Formula 1.

2. The coil substrate of claim 1, A wiring width W1 of the first coil wiring and a wiring width W2 of the second coil wiring satisfy the relationship of Equation 2. 1 / 2≦W1 / W2<1...Equation 2.

3. The coil substrate of claim 1, Among the plurality of coil wirings, there is a third coil wiring that is located in the innermost layer in the state where it is wound in the substantially cylindrical shape, A wiring width W1 of the first coil wiring and a wiring width W3 of the third coil wiring satisfy the relationship of Equation 3. W1=W3...Equation 3.

4. The coil substrate of claim 1, a virtual line that connects the winding start point and the center of the cylindrical coil substrate is provided on the cylindrical cross section of the motor coil substrate; The end of the winding does not exceed the imaginary line.

5. The coil substrate of claim 4, the plurality of coil wirings include U-phase, V-phase, and W-phase coil wirings, The circumferential distance (d) between the virtual line and the winding end is greater than 0 and is equal to or less than the circumferential length (D) of the coil wiring of any one of the U-phase, V-phase, and W-phase coil wirings located in the innermost layer when wound in the approximately cylindrical shape.

6. The coil substrate of claim 4, a first insulating layer is formed on the first surface of the resin substrate; a first side at one end in the longitudinal direction of the resin substrate is a side at one end in the longitudinal direction of the first insulating layer, and the side at one end of the first insulating layer is defined as the winding start point; a second side on the other end side in the longitudinal direction of the resin substrate is a side on the other end side in the longitudinal direction of the first insulating layer, and the side on the other end side of the first insulating layer is defined as the winding end; the imaginary line is a straight line connecting the winding start point of the first insulating layer and the center of the cylindrical coil substrate, When the coil substrate is wound into a substantially cylindrical shape, the winding end of the first insulating layer does not exceed the imaginary line.

7. The coil substrate of claim 4, a second insulating layer is formed on the second surface of the resin substrate; a first side at one end in the longitudinal direction of the resin substrate is a side at one end in the longitudinal direction of the second insulating layer, and the side at one end of the second insulating layer is defined as the winding start point; a second side on the other end side in the longitudinal direction of the resin substrate is a side on the other end side in the longitudinal direction of the second insulating layer, and the side on the other end side of the second insulating layer is defined as the winding end; the imaginary line is a straight line connecting the winding start point of the second insulating layer and the center of the cylindrical coil substrate, When the coil substrate is wound into a substantially cylindrical shape, the winding end of the second insulating layer does not exceed the imaginary line.

8. The coil substrate of claim 1, The coil wiring is a first coil wiring on the first surface forming a half turn and a second coil wiring on the second surface forming a half turn; The first coil wiring and the second coil wiring are connected by a through hole or a via hole.

9. The coil substrate of claim 1, The coil wiring is forming a spiral with a first coil wiring on the first surface and a spiral with a second coil wiring on the second surface; The first coil wiring and the second coil wiring are connected by a through hole or a via hole.

10. A coil substrate for a motor formed by winding the coil substrate of claim 1 into the substantially cylindrical shape.

11. A motor formed by providing one of the motor coil substrate and the magnet according to claim 10 on a rotor and providing the other on a stator.

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