Coil substrate, coil substrate for motor, and motor

Abstract

To provide a coil substrate which can make a cross-sectional shape of a coil substrate for a motor circular, a coil substrate for a motor using the coil substrate, and a motor.SOLUTION: A coil substrate having a resin substrate 10 having a first surface 10F and a second surface 10B opposite to the first surface, and a plurality of coil wires arranged in a longitudinal direction of the resin substrate is composed of a first region R1 positioned in the vicinity of an end in a longitudinal direction of the resin substrate and a second region R2 positioned adjacent to the first region R1, the coil wires are composed of first conductor layers 100 and 200 and second conductor layers 150 and 250 coating the first conductor layers, the plurality of coil wires are a first coil wire 40 formed in the first region R1 and a second coil wire 50 formed in the second region R2, and thickness T1 of the second conductor layers of the first coil wire and thickness T2 of the second conductor layers of the second coil wire satisfy a relation of T1>T2.SELECTED DRAWING: Figure 4

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 substrate comprising a resin substrate and a coil formed of coil wiring on the resin substrate. The coil wiring in Patent Document 1 is formed of a copper pattern and an electrolytic plating film that covers the copper pattern. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2022-78391 Summary of the Invention

[0004] <Issues of Patent Document 1> A coil substrate for a motor is formed by winding a core material into a cylindrical shape. In this case, if the end of the coil substrate does not have enough rigidity, the coil substrate cannot be properly formed along the outer periphery of the core material at the beginning or end of winding, and the cross-sectional shape of the motor coil substrate may not be a perfect circle. In addition, the motor coil substrate may be deformed over time or due to external forces.

[0005] In the technology of Patent Document 1, the thickness of the coil wiring is uniform regardless of the position of the wiring on the coil substrate. This may result in insufficient rigidity at the ends of the coil substrate, making it difficult to properly form the coil substrate along the outer periphery of the core material. [Means for solving the problem]

[0006] 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. The coil substrate includes a first region (R1) located near an end portion in the longitudinal direction of the resin substrate and a second region (R2) located adjacent to the first region (R1). The coil wiring includes a first conductor layer and a second conductor layer covering the first conductor layer. The plurality of coil wirings include a first coil wiring formed in the first region (R1) and a second coil wiring formed in the second region (R2). The thickness T1 of the second conductor layer of the first coil wiring and the thickness T2 of the second conductor layer of the second coil wiring satisfy the relationship of Formula 1. T1>T2 ···· Formula 1

[0007] The coil substrate is wound cylindrically using a core material to form a coil substrate for a motor. At this time, if the rigidity at the end portion in the longitudinal direction of the coil substrate is insufficient, the coil substrate cannot be well formed along the outer peripheral shape of the core material at the start or end of winding, and the cross-sectional shape of the coil substrate for the motor may not become a perfect circular shape. In addition, it is conceivable that the coil substrate for the motor may be deformed over time or by an external force.

[0008] In the coil substrate of the present invention, the thickness T1 of the second conductor layer of the first coil wiring formed in the first region located near the end portion in the longitudinal direction is made larger than the thickness T2 of the second conductor layer of the second coil wiring formed in the second region located adjacent to the first region. Thereby, the rigidity at the end portion in the longitudinal direction of the coil substrate can be increased. As a result, it becomes possible to well form the coil substrate along the outer peripheral shape of the core material at the start or end of winding, and the cross-sectional shape of the coil substrate for the motor can be made into a perfect circular shape. In addition, deformation due to changes over time or external forces can be suppressed.

[0009] In the coil substrate of the present invention, the thickness T1 of the second conductor layer of the first coil wiring and the thickness T2 of the second conductor layer of the second coil wiring satisfy the relationship of Formula 2. 1<T1 / T2<1.5 ···· Formula 2

[0010] In the coil substrate of the present invention, by setting 1 < T1 / T2, the rigidity at the longitudinal end of the coil substrate can be surely increased. Further, by setting T1 / T2 < 1.5, the thickness T1 of the second conductor layer at the longitudinal end of the coil substrate does not become excessive, and the width of the first conductor layer does not become too small. As a result, an increase in the resistance of the coil wiring and a decrease in current can be prevented. Thereby, the motor performance can be ensured.

[0011] In the coil substrate of the present invention, the width W1 of the first conductor layer of the first coil wiring and the width W2 of the first conductor layer of the second coil wiring satisfy the relationship of Equation 3. W1 < W2 ··· Equation (3)

[0012] In the coil substrate, when the first conductor layer is coated by electrolytic plating as the second conductor layer to form the coil wiring, the first conductor layer in the first coil wiring located at the longitudinal end of the substrate has no conductor layer adjacent to the end side, so the current distribution becomes concentrated. When the current distribution is concentrated, the second conductor layer is formed thicker than the first conductor layer in the second coil wiring located at the central portion in the longitudinal direction of the substrate. In that case, the gap between adjacent coil wirings becomes narrow, and there is a possibility of a short circuit occurring.

[0013] In the coil substrate of the present invention, the width W1 of the first conductor layer of the first coil wiring formed in the first region located near the longitudinal end is made smaller than the width W2 of the first conductor layer of the second coil wiring formed in the second region adjacent to the first region. Thereby, even when the second conductor layer of the first coil wiring is formed thicker than the second conductor layer of the second coil wiring, the wiring distance between adjacent coil wirings can be ensured. As a result, a short circuit between adjacent coil wirings can be prevented.

[0014] Furthermore, if the width of the coil wiring near the longitudinal ends of the substrate is uneven compared to the width of the coil wiring at the longitudinal center of the substrate, the cross-sectional shape of the motor coil substrate formed by winding the coil substrate into a cylindrical shape will be polygonal, resulting in corners. Adjacent coil wiring may come into contact inside the corners, causing short circuits. If the cross-sectional shape of the motor coil substrate is polygonal, when the motor coil substrate is housed in a motor housing, the gap between the coil substrate and the motor housing will be uneven, resulting in reduced motor performance. In the coil substrate of the present invention, the wiring widths of the first and second coil wiring can be made uniform, thereby preventing the formation of corners and allowing the cross-sectional shape of the motor coil substrate to be a perfect circle. Furthermore, reduced motor performance can be prevented.

[0015] In the coil substrate of the present invention, the first conductor layer of the first coil wiring is formed with a plurality of conductor layers, and the conductor-to-conductor distance of the first conductor layer is S1, and the first conductor layer of the second coil wiring is formed with a plurality of conductor layers, and the conductor-to-conductor distance of the first conductor layer is S2, and the conductor-to-conductor distance S1 of the first coil wiring and the conductor-to-conductor distance S2 of the second coil wiring satisfy the relationship of Equation 4. S1>S2...Formula 4

[0016] In the coil substrate of the present invention, the inter-conductor distance S1 of the first conductor layer of the first coil wiring formed in the first region located near the longitudinal end is set to be larger than the inter-conductor distance S2 of the first conductor layer of the second coil wiring formed in the second region located adjacent to the first region. This ensures that the inter-conductor distances of adjacent coil wirings are uniform even if the second conductor layer of the first coil wiring is formed thicker than the second conductor layer of the second coil wiring. As a result, short circuits between adjacent coil wirings can be prevented.

[0017] In the coil substrate of the present invention, the thickness H1 of the first coil wiring and the thickness H2 of the second coil wiring satisfy the relationship of formula 5. H1>H2...Equation 5 By making H1 > H2, it is possible to reliably increase the rigidity of the coil substrate at its longitudinal ends. When a motor coil substrate is obtained by winding the coil substrate into a cylindrical shape, the ends of the coil substrate have rigidity relative to the core material used for winding. Therefore, at the beginning of winding the coil substrate, the increased rigidity relative to the core material makes it easier to wind, and at the end of winding the coil substrate, deformation due to external forces can be suppressed.

[0018] In the coil substrate of the present invention, the coil wiring forms a half turn with coil wiring F on the first surface and a half turn with coil wiring B on the second surface, and the coil wiring F and the coil wiring B are connected by a through hole or a via hole.

[0019] In the coil substrate of the present invention, a coil is formed by electrically connecting a half turn of coil wiring F on the first surface and a half turn of coil wiring B on the second surface via a through hole or a via hole. A coil substrate can be realized that can increase the rigidity at the longitudinal end portions while forming half-turn coil wiring on each of the first and second surfaces.

[0020] In the coil substrate of the present invention, the coil wiring forms a spiral with the coil wiring F on the first surface and a spiral with the coil wiring B on the second surface, and the coil wiring F and the coil wiring B are connected by a through hole or a via hole.

[0021] In the coil substrate of the present invention, a coil is formed by electrically connecting the spiral of coil wiring F on the first surface and the spiral of coil wiring B on the second surface via a through hole or a via hole. A coil substrate can be realized that can increase the rigidity of the longitudinal end portions while forming spiral coil wiring on the first or second surface.

[0022] The motor coil substrate of the present invention is formed by winding the above-mentioned coil substrate into a substantially cylindrical shape. Since the motor coil substrate is formed using a coil substrate that can increase the rigidity at the longitudinal ends, the cross section of the motor coil substrate can be made into a perfect circle. This ensures the performance of the motor.

[0023] The motor of the present invention is formed by providing one of the motor coil substrate and magnet on the rotor and the other on the stator. By forming the motor coil substrate using a coil substrate that can increase the rigidity at the longitudinal ends and forming the motor using a motor coil substrate with a perfect circular shape, a motor with ensured performance and reliability can be obtained. [Brief explanation of the drawings]

[0024] [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] 3 is a partially enlarged view of the area A in FIG. 2, showing the vicinity of one end side in the longitudinal direction of the flexible substrate. [Figure 5] 3 is a partially enlarged view of the area B in FIG. 2, showing the vicinity of the other end side in the longitudinal direction of the flexible substrate. [Figure 6] 1 is a perspective view schematically showing a motor coil substrate using the coil substrate of the embodiment; [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] FIG. 10 is a top view showing a coil substrate of a modified example. [Figure 9] FIG. 10 is a bottom view showing a coil substrate of a modified example. DETAILED DESCRIPTION OF THE INVENTION

[0025] [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.

[0026] 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.

[0027] 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.

[0028] As shown in FIGS. 1 to 3, the flexible substrate 10 has a first region R1 located near one end in the longitudinal direction, a second region R2 located adjacent to the first region R1, and a third region R3 located adjacent to the second region R2 and near the other end in the longitudinal direction. As shown in FIG. 2, the first region R1, the second region R2, and the third region R3 are located on the first surface 10F and the second surface 10B of the flexible substrate 10. In this embodiment, of the multiple coils arranged along the longitudinal direction of the flexible substrate 10, the coil 31U (first coil wiring) arranged at one end in the longitudinal direction is formed in the first region R1. The coil 38W (third coil wiring) arranged at the other end in the longitudinal direction is formed in the third region R3. The coils 32U to 38U, 31V to 38V, and 31W to 37W (second coil wiring) arranged in the center of the longitudinal direction are formed in the second region R2. 1 and 3, the flexible substrate 10 has a region divided into two regions: a fourth region R4 at one end in the longitudinal direction and a fifth region R5 at the other end in the longitudinal direction. The fourth region R4 includes a first side E1, and the fifth region R5 includes a second side E2.

[0029] 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 fourth region R4. The V-phase terminal 40V is arranged in the fifth region R5. 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.

[0030] 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.

[0031] 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.

[0032] As shown in FIGS. 1 and 3, starting end 20US of U-phase coil 20U is located within fourth region R4. End 20UE of U-phase coil 20U is located within fifth region R5. 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 end 20UE. Eight coils 31U to 38U are connected to each other by inter-coil connection wiring 50U.

[0033] Each of the eight coils 31U to 38U is formed such that the coil wiring F, which constitutes half of one turn, is formed on the first surface 10F side, and the coil wiring B, which constitutes the remaining half turn, is formed on the second surface 10B side, with adjacent turns being offset from one another. The coil wiring F and the coil wiring B are electrically connected by through holes or via holes formed in the flexible substrate 10.

[0034] 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.

[0035] 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.

[0036] As shown in FIGS. 1, 2, and 3, a portion of the wiring (coil wiring B) on the second surface 10B side of the coil 31U overlaps a portion of the wiring (coil wiring F) on the first surface 10F side of the adjacent coil 32U via the flexible substrate 10. Furthermore, a portion of the wiring (coil wiring B) on the second surface 10B side of the coil 32U overlaps a portion of the wiring (coil wiring F) on the first surface 10F side of the adjacent coil 33U. Furthermore, a portion of the wiring (coil wiring B) on the second surface 10B side of the coil 33U overlaps a portion of the wiring (coil wiring F) on the first surface 10F side of the adjacent coil 34U. Furthermore, a portion of the wiring (coil wiring B) on the second surface 10B side of the coil 34U overlaps a portion of the wiring (coil wiring F) on the first surface 10F side of the adjacent coil 35U. Furthermore, a portion of the wiring (coil wiring B) on the second surface 10B side of the coil 35U overlaps a portion of the wiring (coil wiring F) on the first surface 10F side of the adjacent coil 36U. Furthermore, a portion of the wiring (coil wiring B) on the second surface 10B side of coil 36U overlaps a portion of the wiring (coil wiring F) on the first surface 10F side of adjacent coil 37U. Further, a portion of the wiring (coil wiring B) on the second surface 10B side of coil 37U overlaps a portion of the wiring (coil wiring F) on the first surface 10F side of adjacent coil 38U.

[0037] 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.

[0038] As shown in FIGS. 1 and 3, a starting end 20VS of the V-phase coil 20V is disposed within a fifth region R5. A terminal end 20VE of the V-phase coil 20V is disposed within a fourth region R4. 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.

[0039] Each of the eight coils 31V to 38V is formed by arranging the coil wiring F, which constitutes half of one turn, on the first surface 10F side, and the coil wiring B, which constitutes the remaining half turn, on the second surface 10B side, with adjacent turns being offset from one another. The coil wiring F and the coil wiring B are electrically connected by through holes or via holes formed in the flexible substrate 10.

[0040] 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.

[0041] 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.

[0042] As shown in FIGS. 1, 2, and 3, a portion of the wiring (coil wiring F) on the first surface 10F side of the coil 31V overlaps a portion of the wiring (coil wiring B) on the second surface 10B side of the adjacent coil 32V via the flexible substrate 10. Furthermore, a portion of the wiring (coil wiring F) on the first surface 10F side of the coil 32V overlaps a portion of the wiring (coil wiring B) on the second surface 10B side of the adjacent coil 33V. Furthermore, a portion of the wiring (coil wiring F) on the first surface 10F side of the coil 33V overlaps a portion of the wiring (coil wiring B) on the second surface 10B side of the adjacent coil 34V. Furthermore, a portion of the wiring (coil wiring F) on the first surface 10F side of the coil 34V overlaps a portion of the wiring (coil wiring B) on the second surface 10B side of the adjacent coil 35V. Furthermore, a portion of the wiring (coil wiring F) on the first surface 10F side of the coil 35V overlaps a portion of the wiring (coil wiring B) on the second surface 10B side of the adjacent coil 36V. Furthermore, a portion of the wiring (coil wiring F) on the first surface 10F side of coil 36V overlaps a portion of the wiring (coil wiring B) on the second surface 10B side of adjacent coil 37V. Furthermore, a portion of the wiring (coil wiring F) on the first surface 10F side of coil 37V overlaps a portion of the wiring (coil wiring B) on the second surface 10B side of adjacent coil 38V.

[0043] 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.

[0044] As shown in FIGS. 1 and 3, a starting end 20WS of the W-phase coil 20W is disposed within a fourth region R4. A terminal end 20WE of the W-phase coil 20W is disposed within a fifth region R5. 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.

[0045] Each of the eight coils 31W to 38W is formed such that the coil wiring F, which constitutes half of one turn, is formed on the first surface 10F side, and the coil wiring B, which constitutes the remaining half turn, is formed on the second surface 10B side, with adjacent turns being offset from one another. The coil wiring F and the coil wiring B are electrically connected by through holes or via holes formed in the flexible substrate 10.

[0046] 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.

[0047] 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.

[0048] As shown in FIGS. 1, 2, and 3, a portion of the wiring (coil wiring B) on the second surface 10B side of the coil 31W overlaps a portion of the wiring (coil wiring F) on the first surface 10F side of the adjacent coil 32W via the flexible substrate 10. Also, a portion of the wiring (coil wiring B) on the second surface 10B side of the coil 32W overlaps a portion of the wiring (coil wiring F) on the first surface 10F side of the adjacent coil 33W. A portion of the wiring (coil wiring B) on the second surface 10B side of the coil 33W overlaps a portion of the wiring (coil wiring F) on the first surface 10F side of the adjacent coil 34W. A portion of the wiring (coil wiring B) on the second surface 10B side of the coil 34W overlaps a portion of the wiring (coil wiring F) on the first surface 10F side of the adjacent coil 35W. A portion of the wiring (coil wiring B) on the second surface 10B side of the coil 35W overlaps a portion of the wiring (coil wiring F) on the first surface 10F side of the adjacent coil 36W. A portion of the wiring (coil wiring B) on the second surface 10B side of the coil 36W overlaps a portion of the wiring (coil wiring F) on the first surface 10F side of the adjacent coil 37W. A portion of the wiring (coil wiring B) on the second surface 10B side of the coil 37W overlaps a portion of the wiring (coil wiring F) on the first surface 10F side of the adjacent coil 38W.

[0049] 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.

[0050] 1 and 3, the interphase connecting wiring 60W connects the end 20WE of the W-phase coil 20W to the terminal connecting wiring 45U. The interphase connecting wiring 60W is formed across the fifth region R5 and the fourth region R4.

[0051] 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 coil wiring F on the first surface 10F, forming a half turn of the coil wiring B on the second surface 10B, and connecting the coil wiring F and the coil wiring B 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.

[0052] Although not shown, the coil wiring F and coil wiring B of each of the U-phase coil 20U, V-phase coil 20V, and W-phase coil 20W, the terminal connection wiring 45U, 45V, and 45W, the inter-coil connection wiring 50U, 50V, and 50W, and the inter-phase connection wiring 60U, 60V, and 60W are covered with an insulating layer. The insulating layer may be formed to conform to the wiring, or it may cover the circuit and fill the spaces between adjacent wiring. The insulating layer prevents the wiring from being exposed, maintaining insulation. The method for forming the insulating layer is not particularly limited, but it can be formed by printing a liquid resin or by electro-deposition of a resin. An example of the resin is polyimide.

[0053] Fig. 4 is a partially enlarged view of range A in Fig. 2, enlarging the vicinity of one longitudinal end of flexible substrate 10. As shown in Fig. 4, among the multiple coils arranged along the longitudinal direction of flexible substrate 10, coil 31U (first coil wiring) arranged at one longitudinal end is formed in first region R1. Furthermore, coil 38V (second coil wiring) arranged in the central portion in the longitudinal direction is formed in second region R2.

[0054] As shown in FIG. 4, each coil wiring constituting the coil 31U is composed of a first conductor layer 100 and a second conductor layer 150 covering the first conductor layer 100. Each coil wiring constituting the coil 38V is composed of a first conductor layer 200 and a second conductor layer 250 covering the first conductor layer 200. The first conductor layers 100, 200 are formed by at least one of electroless plating and electrolytic plating. For example, the first conductor layers 100, 200 may be formed by forming a metal foil layer containing copper or nickel on the flexible substrate 10, forming an electroless plated layer on the metal foil layer, and forming an electrolytic plated layer on the electroless plated layer. The second conductor layers 150, 250 are formed by electrolytic plating.

[0055] When the second conductor layers 150, 250 are formed by electrolytic plating, the second conductor layer 150 of the coil wiring located at the longitudinal end of the flexible substrate 10 has no adjacent conductor layer on the outside (first side E1), so the current distribution is concentrated. For this reason, the second conductor layer 150 is formed thicker than the second conductor layer 250 of the coil wiring located at the longitudinal center. In the example shown in Fig. 4, the second conductor layer 150 of the coil wiring constituting the coil 31U is formed thicker than the second conductor layer 250 of the coil wiring of the adjacent coil 38V.

[0056] Therefore, in order to prevent a short circuit from occurring between adjacent coil wirings in the coil 31U, the width W1 of the first conductor layer 100 of the coil 31U formed in the first region R1 is formed to be smaller than the width W2 of the first conductor layer 200 of the coil 38V formed in the second region R2. That is, the width W1 of the first conductor layer 100 of the coil 31U (the first coil wiring) and the width W2 of the first conductor layer 200 of the coil 38V (the second coil wiring) satisfy the relationship of Equation 3. W1 < W2 ···· (Equation 3) Note that the width W1 of the first conductor layer 100 and the width W2 of the first conductor layer 200 are not particularly limited, but are preferably formed to be 80 to 500 μm.

[0057] In addition, in the first region R1, a plurality (three in FIG. 4) of the first conductor layers 100 constituting the coil 31U are formed, and the distance between these first conductor layers 100 is defined as the conductor-to-conductor distance S1. In the second region R2, a plurality (three in FIG. 4) of the first conductor layers 200 constituting the coil 38V are formed, and the distance between these first conductor layers 200 is defined as the conductor-to-conductor distance S2. The conductor-to-conductor distance S1 of the coil 31U formed in the first region R1 is formed to be larger than the conductor-to-conductor distance S2 of the coil 38V formed in the second region R2. That is, the conductor-to-conductor distance S1 of the coil 31U (the first coil wiring) and the conductor-to-conductor distance S2 of the coil 38V (the second coil wiring) satisfy the relationship of Equation 4. S1 > S2 ···· (Equation 4) Note that the conductor-to-conductor distance S1 of the first coil wiring and the conductor-to-conductor distance S2 of the second coil wiring are not particularly limited, but are preferably formed to be 50 to 200 μm.

[0058] In addition, as described above, the second conductor layer 150 of the coil wiring of the coil 31U is formed to be thicker than the second conductor layer 250 of the coil wiring of the adjacent coil 38V. That is, the thickness T1 of the second conductor layer 150 of the coil 31U (the first coil wiring) and the thickness T2 of the second conductor layer 250 of the coil 38V (the second coil wiring) satisfy the relationship of Equation 1. T1 > T2 ···· (Equation 1)

[0059] Furthermore, the thickness T1 of the second conductor layer 150 of the coil 31U (first coil wiring) and the thickness T2 of the second conductor layer 250 of the coil 38V (second coil wiring) satisfy the relationship of Equation 2. 1 < T1 / T2 < 1.5 ···· (Equation 2) The thickness T1 of the second conductor layer 150 of the first coil wiring and the thickness T2 of the second conductor layer 250 of the second coil wiring are not particularly limited, but are preferably formed to be 10 to 100 μm.

[0060] In the coil substrate 2 of this embodiment, the thickness H1 of the first coil wiring and the thickness H2 of the second coil wiring satisfy the relationship of Equation 5. H1 > H2 ···· (Equation 5) By making H1 > H2, the rigidity at the longitudinal end of the coil substrate 2 can be surely increased. When obtaining the motor coil substrate 550 by winding the coil substrate 2 into a cylindrical shape, the coil substrate 2 has rigidity at the end with respect to the core material for winding. Therefore, at the start of winding the coil substrate 2, the rigidity with respect to the core material increases, making it easier to wind, and at the end of winding the coil substrate 2, deformation against external forces can be suppressed. The thicknesses H1 and H2 of the coil wiring are not particularly limited, but are preferably formed to be 20 to 200 μm.

[0061] The pitch P between adjacent coil wirings in the coil 31U is substantially equal to the pitch P between adjacent coil wirings in the coil 38V. The width W of the first coil wiring 40 in the coil 31U is substantially equal to the width W of the second coil wiring 50 in the coil 38V. The thickness H of the first conductor layer 100 of the first coil wiring 40 in the coil 31U is substantially equal to the thickness H of the first conductor layer 200 of the second coil wiring 50 in the coil 38V. The thickness of the first conductor layer of the coil wiring is not particularly limited, but is preferably 10 to 100 μm. That is, the pitch P of the coil wiring, the width W of the coil wiring, and the thickness H of the first conductor layer are common to the first region R1 and the second region R2. The pitch P of the coil wiring and the width W of the coil wiring may be different between the first region R1 and the second region R2. The width W of the coil wiring is not particularly limited, but is preferably 100 to 700 μm.

[0062] Note that the coils 32U to 38U, 31V to 37V, and 31W to 37W other than the coil 38V formed in the second region R2 are also formed to the same dimensions as the coil 38V. That is, the width of the first conductor layer 200 is W2, the inter-conductor distance is S2, the thickness of the second conductor layer 250 is T2, the pitch of the coil wiring is P, and the width of the second coil wiring 50 is W.

[0063] In the example shown in FIG. 4, among the coil wirings constituting the coil 31U, not only the coil wiring closest to the first side E1 but also the second conductor layer 150 of multiple coil wirings (three in FIG. 4) counting from the first side E1 is formed thicker than the second conductor layer 250 of the other coil wirings. This is because, since the multiple coil wirings (three in FIG. 4) are continuous, the coil 31U is constituted by a single coil wiring, and therefore a current equivalent to that of the coil wiring at the end where the current distribution is concentrated flows through the multiple coil wirings. Note that the second conductor layer 150 of only the coil wiring closest to the first side E1 may be formed thick, or the second conductor layer 150 of some (e.g., two) of the coil wirings of the coil 31U may be formed thick. Furthermore, not only the second conductor layer 150 of the coil 31U but also the second conductor layer 250 of at least some of the coil wirings of the coils adjacent to the coil 31U may be formed thick. In addition, the number of coil wirings counted from the first side E1 of the coil wiring in which the second conductor layer 150 is formed thicker than the second conductor layer 250 of the other coil wirings is not particularly limited, but it is sufficient to have one or more, and it is preferable that it be less than five.

[0064] The first region R1 is a region located near one end of the flexible substrate 10 in the longitudinal direction. In the embodiment, the first region R1 is a region including the coil 31U arranged at one end in the longitudinal direction. The first region R1 may be a region including only one coil wiring of the coil 31U that is closest to the first side E1, or may be a region including some (e.g., two) coil wirings of the coil 31U. The first region R1 may also be a region including not only the coil 31U but also at least some of the coil wirings of the coil adjacent to the coil 31U. The first region R1 may also coincide with a region where a thick electroplated film (second conductor layer 150) is formed due to non-uniform current distribution during electroplating.

[0065] Although not shown, the coils 31U and 38V in the range C in FIG. 2 are also formed to have the same dimensions as the coils 31U and 38V in the range A described above.

[0066] FIG. 5 is a partially enlarged view showing an enlarged view of the vicinity of the other end side in the longitudinal direction of the flexible substrate 10, which is the range B in FIG. 2. As shown in FIG. 5, among the plurality of coils arranged along the longitudinal direction of the flexible substrate 10, the coil 38W (third coil wiring) arranged on the other end side in the longitudinal direction is formed in the third region R3. Further, the coil 31V (second coil wiring) arranged at the central portion in the longitudinal direction is formed in the second region R2.

[0067] As shown in FIG. 5, each coil wiring constituting the coil 31V is composed of a first conductor layer 200 and a second conductor layer 250 covering the first conductor layer 200. Each coil wiring constituting the coil 38W is composed of a first conductor layer 300 and a second conductor layer 350 covering the first conductor layer 300. When the second conductor layers 250 and 350 are formed by electrolytic plating, the second conductor layer 350 of the coil wiring located at the longitudinal end of the flexible substrate 10 has no conductor layer adjacent to the outside (the second side E2 side), so the current distribution is concentrated. For this reason, the second conductor layer 350 is formed thicker than the second conductor layer 250 in the coil wiring located at the central portion in the longitudinal direction. In the example shown in FIG. 5, the second conductor layer 350 of the coil wiring constituting the coil 38W is formed thicker than the second conductor layer 250 of the coil wiring of the adjacent coil 31V.

[0068] Therefore, in order to prevent a short circuit from occurring between adjacent coil wirings in the coil 38W, the width W3 of the first conductor layer 300 of the coil 38W formed in the third region R3 is formed smaller than the width W2 of the first conductor layer 200 of the coil 31V formed in the second region R2. That is, the width W3 of the first conductor layer 300 of the coil 38W (third coil wiring) and the width W2 of the first conductor layer 200 of the coil 31V (second coil wiring) satisfy the relationship of Equation 6. W3 < W2 ···· (Equation 6) The width W3 of the first conductor layer 300 is not particularly limited, but is preferably formed to be 80 to 500 μm.

[0069] In addition, in the third region R3, a plurality (three in FIG. 5) of first conductor layers 300 constituting the coil 38W are formed, and the distance between these first conductor layers 300 is defined as the conductor-to-conductor distance S3. In the second region R2, a plurality (three in FIG. 5) of first conductor layers 200 constituting the coil 31V are formed, and the distance between these first conductor layers 200 is defined as the conductor-to-conductor distance S2. The conductor-to-conductor distance S3 of the coil 38W formed in the third region R3 is formed to be larger than the conductor-to-conductor distance S2 of the coil 31V formed in the second region R2. That is, the conductor-to-conductor distance S3 of the coil 38W (third coil wiring) and the conductor-to-conductor distance S2 of the coil 31V (second coil wiring) satisfy the relationship of Equation 7. S3 > S2 ···· (Equation 7) Note that the conductor-to-conductor distance S3 of the third coil wiring is not particularly limited, but is preferably formed to be 50 to 200 μm.

[0070] Also, as described above, the second conductor layer 350 of the coil wiring of the coil 38W is formed thicker than the second conductor layer 250 of the coil wiring of the adjacent coil 31V. That is, the thickness T3 of the second conductor layer 350 of the coil 38W (third coil wiring) and the thickness T2 of the second conductor layer 250 of the coil 31V (second coil wiring) satisfy the relationship of Equation 8. T3 > T2 ···· (Equation

[0071] [[ID=I3]] Furthermore, the thickness T3 of the second conductor layer 350 of the coil 38W (third coil wiring) and the thickness T2 of the second conductor layer 250 of the coil 31V (second coil wiring) satisfy the relationship of Equation 9. 1 < T3 / T2 < 1.5 ···· (Equation 9) Note that the thickness T3 of the second conductor layer 350 of the third coil wiring is not particularly limited, but is preferably formed to be 10 to 100 μm.

[0072] In the coil substrate 2 of the present embodiment, the thickness H3 of the third coil wiring and the thickness H2 of the second coil wiring satisfy the relationship of Equation 10. H3 > H2 ···· (Equation 10) By making H3 > H2, it is possible to reliably increase the rigidity of the longitudinal ends of the coil substrate 2. When the motor coil substrate 550 is obtained by winding the coil substrate 2 into a cylindrical shape, the ends of the coil substrate 2 have rigidity relative to the core material used for winding. Therefore, at the beginning of winding the coil substrate 2, the rigidity relative to the core material is increased, making winding easier, and at the end of winding the coil substrate 2, deformation due to external forces can be suppressed. The thickness H3 of the third coil wiring is not particularly limited, but is preferably formed to be 20 to 200 μm.

[0073] The pitch P of adjacent coil wiring in coil 38W is substantially equal to the pitch P of adjacent coil wiring in coil 31V. The width W of the third coil wiring 60 in coil 38W is substantially equal to the width W of the second coil wiring 50 in coil 31V. The thickness H of the first conductor layer 300 of the third coil wiring 60 in coil 38W is substantially equal to the thickness H of the first conductor layer 200 of the second coil wiring 50 in coil 31V. That is, the coil wiring pitch P, coil wiring width W, and first conductor layer thickness H are common to the third region R3 and the second region R2. The coil wiring pitch P and coil wiring width W may be different between the third region R3 and the second region R2.

[0074] Note that the coils 32U to 38U, 32V to 38V, and 31W to 37W other than the coil 31V formed in the second region R2 are also formed to the same dimensions as the coil 31V. That is, the width of the first conductor layer 200 is W2, the inter-conductor distance is S2, the thickness of the second conductor layer 250 is T2, the pitch of the coil wiring is P, and the width of the second coil wiring 50 is W.

[0075] In the example shown in FIG. 5, among the coil wirings constituting the coil 38W, not only the coil wiring closest to the second side E2 but also the second conductor layers 350 of multiple coil wirings (three in FIG. 5) counting from the second side E2 are formed thicker than the second conductor layers 250 of the other coil wirings. This is because, since the multiple coil wirings (three in FIG. 5) are continuous, the coil 38W is constituted by a single coil wiring, and therefore a current equivalent to that of the coil wiring at the end where the current distribution is concentrated flows through the multiple coil wirings. Note that the second conductor layer 350 of only the coil wiring closest to the second side E2 may be formed thick, or the second conductor layer 350 of some (e.g., two) of the coil wirings of the coil 38W may be formed thick. Furthermore, not only the second conductor layer 350 of the coil 38W but also the second conductor layer 250 of at least some of the coil wirings of the coils adjacent to the coil 38W may be formed thick. In addition, the number of coil wiring strands counted from the second side E2 of the coil wiring that forms the second conductor layer 350 thicker than the second conductor layer 250 of the other coil wiring strands is not particularly limited, but it is sufficient that the number is one or more, and it is preferable that the number is less than five.

[0076] The third region R3 is a region located near the other longitudinal end of the flexible substrate 10. In the embodiment, the third region R3 is a region including the coil 38W arranged on the other longitudinal end side. The third region R3 may be a region including only one coil wiring of the coil 38W that is closest to the second side E2, or may be a region including some (e.g., two) coil wirings of the coil 38W. The third region R3 may also be a region including not only the coil 38W but also at least some of the coil wirings of the coil adjacent to the coil 38W. The third region R3 may also coincide with a region where the electroplated film (second conductor layer 350) is formed thick due to non-uniform current distribution during electroplating.

[0077] Although not shown, the coils 38W and 31V in the range D in FIG. 2 are also formed to have the same dimensions as the coils 38W and 31V in the range B described above.

[0078] The width W1, inter-conductor distance S1, and thickness T1 of the first conductor layer 100 in the coil 31U are approximately equal to the width W3, inter-conductor distance S3, and thickness T3 of the second conductor layer 350 in the coil 38W. The width W1, inter-conductor distance S1, and thickness T1 of the first conductor layer 300 in the coil 31U may be different from the width W3, inter-conductor distance S3, and thickness T3 of the second conductor layer 350 in the coil 38W.

[0079] [Motor coil substrate] FIG. 6 is a perspective view schematically illustrating a motor coil substrate 550 using the coil substrate 2 of the embodiment (FIGS. 1 to 5). As shown in FIG. 6, the coil substrate 2 of the embodiment is wound cylindrically around a core material to form the motor coil substrate 550 for a motor. When the coil substrate 2 is wound cylindrically, 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, and the coil substrate 2 is wound multiple times around an axis extending in the perpendicular direction (an axis extending parallel to the first side E1). The number of times the coil substrate 2 is wound is not particularly limited, but is preferably between two and ten times. In this embodiment, the number of times the coil substrate 2 is wound is approximately two times. When the coil substrate 2 is wound cylindrically, 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. When coil substrate 2 is wound into a cylindrical shape, first surface 10F of flexible substrate 10 may be disposed on the inner circumferential side, and second surface 10B may be disposed on the outer circumferential side.

[0080] The coil substrate 2 is wound such that the coils 31U, 32U, 33U, and 34U in the fourth region R4 and the coils 35U, 36U, 37U, and 38U in the fifth region R5 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 fourth region R4 and the coils 34V, 33V, 32V, and 31V in the fifth region R5 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 fourth region R4 and the coils 35W, 36W, 37W, and 38W in the fifth region R5 overlap each other in the radial direction. As a result, the coil substrate 2 is wound such that the U-phase, V-phase, and W-phase are repeated four times per turn. Note that the coil substrate 2 may be configured such that the U-phase, V-phase, and W-phase are repeated one to three times or five or more times per turn.

[0081] 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 by 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.

[0082] As an example in this embodiment, the width W1 of the first conductor layer 200 of the first coil wiring is 375 μm, the thickness H of the first conductor layer 200 of the first coil wiring is 15 μm, the thickness T1 of the second conductor layer 150 of the first coil wiring is 30 μm, and the distance between conductors S1 of the first coil wiring is 85 μm; the width W2 of the first conductor layer 200 of the second coil wiring is 400 μm, the thickness H of the first conductor layer 200 of the second coil wiring is 15 μm, the thickness T2 of the second conductor layer 250 of the second coil wiring is 20 μm, and the distance between conductors S2 of the second coil wiring is 65 μm; the width W of the coil wiring is 440 μm, the thickness H1 of the first coil wiring is 45 μm, and the thickness H2 of the second coil wiring is 25 μm.

[0083] [Motor] FIG. 7 is a cross-sectional view schematically illustrating a motor 600 using the motor coil substrate 550 (FIG. 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.

[0084] The motor coil substrate 550 is disposed inside a cylindrical yoke 560 (an example of a housing). The outer peripheral surface OC of the motor coil substrate 550 and the inner peripheral surface 560a of the yoke 560 are fixed by adhesive. The inner peripheral surface IC of the motor coil substrate 550 and the outer peripheral surface 570a of the magnet 570 are disposed so as to face each other in the radial direction with a predetermined gap therebetween. When the motor coil substrate 550, which has a perfect circular 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. By making the gap uniform, heat does not build up even when the motor 600 is operating, and deterioration of motor performance is suppressed.

[0085] 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.

[0086] [Effects of the embodiment] As described above, the configurations of the coil substrate 2 (FIGS. 1 to 5), the motor coil substrate 550 (FIG. 6), and the motor 600 (FIG. 7) of the embodiment have been described. As described above, in the coil substrate 2 of the embodiment, when the first conductor layers 100, 200, and 300 are covered with the second conductor layers 150, 250, and 350 to form the coil wiring, the first conductor layers 100 and 300 located at the longitudinal ends have no adjacent conductor layers on the end side, resulting in current concentration. When the current concentration occurs, the second conductor layers 150 and 350 are formed thicker than the first conductor layer 200 located in the longitudinal center of the substrate. Therefore, if all the coil wiring is formed to the same dimensions, the gap between adjacent coil wirings at the longitudinal ends becomes narrow, which may cause a short circuit.

[0087] In the coil substrate 2 of this embodiment, the thickness T1 of the second conductor layer 150 of the coil 31U formed in the first region R1 located near one longitudinal end is set to be greater than the thickness T2 of the second conductor layer 250 of the coil 38V, etc. formed in the second region R2 located adjacent to the first region R1. Similarly, the thickness T3 of the second conductor layer 350 of the coil 38W formed in the third region R3 located near the other longitudinal end is set to be greater than the thickness T2 of the second conductor layer 250 of the coil 31V, etc. formed in the second region R2 located adjacent to the third region R3. This increases the rigidity of the longitudinal ends of the coil substrate 2. As a result, the coil substrate 2 can be properly shaped to fit the outer periphery of the core material at the start or end of winding, allowing the cross-sectional shape of the motor coil substrate 550 to be a perfect circle. Furthermore, deformation over time or due to external forces can be suppressed.

[0088] In the coil substrate 2 of the embodiment, by setting 1 < T1 / T2 or 1 < T3 / T2, the rigidity at the longitudinal end of the coil substrate 2 can be surely increased. Further, by setting T1 / T2 < 1.5 or T3 / T2 < 1.5, the thicknesses T1 and T3 of the second conductor layers 150 and 350 at the longitudinal end of the coil substrate 2 do not become excessive, and the widths of the first conductor layers 100 and 300 do not become too small. As a result, an increase in the resistance of the coil wiring and a decrease in the current can be prevented. Thereby, the motor performance can be ensured.

[0089] In the coil substrate, when forming the coil wiring by covering the first conductor layers 100, 200, and 300 with the second conductor layers 150, 250, and 350, the first conductor layers 100 and 300 located at the longitudinal ends do not have conductor layers adjacent to the end sides, so the current distribution concentrates. When the current distribution concentrates, the second conductor layers 150 and 350 are formed thicker than the first conductor layer 200 located at the center in the longitudinal direction of the substrate. Therefore, when forming all the coil wirings with the same dimensions, the gap between adjacent coil wirings at the longitudinal end becomes narrow, and a short circuit may occur.

[0090] In the coil substrate 2 of the embodiment, the width W1 of the first conductor layer 100 of the coil 31U formed in the first region R1 located near the end on one end side in the longitudinal direction is made smaller than the width W2 of the first conductor layer 200 of the coil 38V or the like formed in the second region R2 adjacent to the first region R1. Similarly, the width W3 of the first conductor layer 300 of the coil 38W formed in the third region R3 located near the end on the other end side in the longitudinal direction is made smaller than the width W2 of the first conductor layer 200 of the coil 31V or the like formed in the second region R2 adjacent to the third region R3. Thereby, even when the second conductor layers 150 and 350 of the coils 31U and 38W are formed thicker than the second conductor layer 250 of the coils 38V and 31V or the like in the second region R2, the wiring distance between adjacent coil wirings can be ensured. As a result, a short circuit between adjacent coil wirings in the vicinity of both longitudinal ends of the coil substrate 2 can be prevented.

[0091] Furthermore, if the width of the coil wiring is non-uniform near the longitudinal ends, the cross-sectional shape of the motor coil substrate 550 formed by winding the coil substrate 2 into a cylindrical shape will be polygonal, resulting in corners. In the coil substrate 2 of the embodiment, the wiring width (width W) of the coil wiring can be made uniform in the first region R1, the third region R3, and the second region R2, thereby preventing corners from being formed and allowing the cross-sectional shape of the motor coil substrate 550 to be a perfect circle. This also prevents a decrease in motor performance.

[0092] In the coil substrate 2 of the embodiment, the inter-conductor distance S1 of the coil 31U formed in the first region R1 located near one longitudinal end is set larger than the inter-conductor distance S2 of the coils 38V, etc. formed in the second region R2 located adjacent to the first region R1. Similarly, the inter-conductor distance S3 of the coil 38W formed in the third region R3 located near the other longitudinal end is set larger than the inter-conductor distance S2 of the coils 31V, etc. formed in the second region R2 located adjacent to the third region R3. This ensures sufficient inter-wiring distance between adjacent coil wirings even when the second conductor layers 150, 350 of the coils 31U, 38W are formed thicker than the second conductor layers 250 of the coils 38V, 31V, etc. As a result, short circuits between adjacent coil wirings near both longitudinal ends of the coil substrate 2 can be prevented.

[0093] In the coil substrate 2 of the embodiment, each coil is formed by electrically connecting a half turn of coil wiring F on the first surface 10F of the flexible substrate 10 to a half turn of coil wiring B on the second surface 10B via a through hole or a via hole. A coil substrate 2 can be realized that can form half-turn coil wiring on each of the first surface 10F and the second surface 10B, while preventing short circuits from occurring between adjacent coil wiring.

[0094] The motor coil substrate 550 of the embodiment is formed using the coil substrate 2 that can increase the rigidity at the longitudinal end portions, so that the cross section of the motor coil substrate 550 can be made into a perfect circle, thereby improving the performance of the motor 600.

[0095] The motor coil substrate 550 of the embodiment is formed using a coil substrate 2 that can increase the rigidity at the longitudinal ends, and the motor 600 of the embodiment is formed using the motor coil substrate 550 that has a perfect circular shape, so a motor with good performance and high reliability can be obtained.

[0096] [Modification of the embodiment] 8 and 9 show a modified example of the embodiment. Fig. 8 is a top view showing a coil substrate 102 of the modified example. Fig. 9 is a bottom view showing a coil substrate 102 of the modified example.

[0097] 8 and 9, 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 modified example, coils 31U, 31V, 31W constituting U-phase coil 20U, V-phase coil 20V, and W-phase coil 20W form a spiral with coil wiring F on first surface 10F and a spiral with coil wiring B on second surface 10B, and coil wiring F and coil wiring B are connected by through holes TH or via holes VH. In addition, in Figures 8 and 9, 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.

[0098] 8 and 9, U-phase terminal 40U, V-phase terminal 40V, W-phase terminal 40W, terminal connecting wires 45U, 45V, 45W, coil wiring F 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, coil wiring B 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.

[0099] The coil wiring F on the first surface 10F constituting the coil 31U and the coil wiring B on the second surface 10B constituting the coil 31U are each formed in a spiral shape (a hexagonal spiral shape). The coil wiring F and the coil wiring B are overlapped via the flexible substrate 10, and the inner peripheral end of the coil wiring F is connected to the inner peripheral end of the coil wiring B via a through hole TH or a via hole VH. As shown in FIG. 8, the outer peripheral end of the coil wiring F of the coil 31U is connected to the U-phase terminal 40U via a terminal connecting wiring 45U. As shown in FIG. 9, the outer peripheral end of the coil wiring B of the coil 31U is connected to one end of the interphase connecting wiring 60U.

[0100] The coil wiring F on the first surface 10F constituting the coil 31V and the coil wiring B on the second surface 10B constituting the coil 31V are each formed in a spiral shape (a hexagonal spiral shape). The coil wiring F and the coil wiring B are overlapped via the flexible substrate 10, and the inner peripheral end of the coil wiring F is connected to the inner peripheral end of the coil wiring B via a through hole TH or a via hole VH. As shown in FIG. 8, the outer peripheral end of the coil wiring F 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. 9, the outer peripheral end of the coil wiring B of the coil 31V is connected to one end of the interphase connecting wiring 60V.

[0101] The coil wiring F on the first surface 10F constituting the coil 31W and the coil wiring B on the second surface 10B constituting the coil 31W are each formed in a spiral shape (a hexagonal spiral shape). The coil wiring F and the coil wiring B are overlapped via the flexible substrate 10, and the inner peripheral end of the coil wiring F is connected to the inner peripheral end of the coil wiring B via a through hole TH or a via hole VH. As shown in FIG. 8, the outer peripheral end of the coil wiring F 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 a through hole TH or a via hole VH. As shown in FIG. 9, the outer peripheral end of the coil wiring B 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 a through hole TH or a via hole VH.

[0102] 8 and 9, in the 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 or 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.

[0103] The coil substrate 102 of the modified example also has the same characteristics as the coil substrate 2 of the embodiment. Specifically, in the coil substrate 102, the thickness T1 of the second conductor layer 150 of the coil wiring formed in the first region R1 located near one longitudinal end of the coil wiring constituting the coil 31U is greater than the thickness T2 of the second conductor layer 250 of the coil 31V, etc., formed in the second region R2 located adjacent to the first region R1. Similarly, the thickness T3 of the second conductor layer 350 of the coil wiring formed in the third region R3 located near the other longitudinal end of the coil wiring constituting the coil 31W is greater than the thickness T2 of the second conductor layer 250 of the coil 31V, etc., formed in the second region R2 located adjacent to the third region R3. This increases the rigidity of the longitudinal ends of the coil substrate 102. As a result, the coil substrate 102 can be properly shaped to fit the outer periphery of the core material at the start or end of winding, allowing the cross-sectional shape of the motor coil substrate 550 to be a perfect circle. Furthermore, deformation due to changes over time or external forces can be suppressed.

[0104] Furthermore, in the modified coil substrate 102, the spiral of the coil wiring F on the first surface 10F and the spiral of the coil wiring B on the second surface 10B are electrically connected via a through hole or a via hole, thereby forming a coil. It is possible to realize a coil substrate 102 that can increase the rigidity at the longitudinal end portions while forming spiral coil wiring on the first surface 10F or the second surface 10B. [Explanation of symbols]

[0105] 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) 31U, 38W coil (first coil wiring) 32U~38U, 31V~38V, 31W~37W Coil (second coil wiring) 40 First coil wiring 50 Second coil wiring 60 Third coil wiring 100, 200, 300 First conductor layer 102 Coil board 150, 250, 350 Second conductor layer 550 Motor coil board 570 Magnet 600 motor 610 Rotor 620 Stator E1 First side E2 Second edge R1 1st area R2 2nd area R3 3rd area R4 4th area R5 5th area S1 Distance between conductors S2 Distance between conductors S3 Distance between conductors T1 Thickness of the second conductor layer T2 Thickness of the second conductor layer T3 Thickness of the second conductor layer W1 Width of the first conductor layer W2 Width of the first conductor layer W3 Width of the first conductor layer H1 Thickness of the first coil wire H2 Thickness of the second coil wiring H3 Third coil wiring thickness H Thickness of the first conductor layer W coil wire width

Claims

1. 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 a longitudinal direction of the resin substrate, The resin substrate includes a first region (R1) located near an end of the resin substrate in the longitudinal direction and a second region (R2) located adjacent to the first region (R1), the coil wiring includes a first conductor layer and a second conductor layer covering the first conductor layer, the plurality of coil wirings are first coil wirings formed in the first region (R1) and second coil wirings formed in the second region (R2), The thickness T1 of the second conductor layer of the first coil wiring and the thickness T2 of the second conductor layer of the second coil wiring satisfy the relationship of Equation 1. T1>T2...Formula 1

2. The coil substrate of claim 1, The thickness T1 of the second conductor layer of the first coil wiring and the thickness T2 of the second conductor layer of the second coil wiring satisfy the relationship of Equation 2. 1<T1 / T2<1.5...Formula 2

3. The coil substrate of claim 1, The width W1 of the first conductor layer of the first coil wiring and the width W2 of the first conductor layer of the second coil wiring satisfy the relationship of Equation 3. W1<W2...Formula 3

4. The coil substrate of claim 3, The first conductor layer of the first coil wiring is formed by a plurality of conductor layers, and a conductor-to-conductor distance of the first conductor layers is S1; The first conductor layer of the second coil wiring is formed of a plurality of conductor layers, and the conductor-to-conductor distance of the first conductor layers is S2; The inter-conductor distance S1 of the first coil wiring and the inter-conductor distance S2 of the second coil wiring satisfy the relationship of Equation 4. S1>S2...Formula 4

5. The coil substrate of claim 3, The thickness H1 of the first coil wiring and the thickness H2 of the second coil wiring satisfy the relationship of Equation 5. H1>H2...Formula 5

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

7. The coil substrate of claim 1, The coil wiring is The coil wiring F on the first surface forms a spiral, and the coil wiring B on the second surface forms a spiral, The coil wiring F and the coil wiring B are connected by a through hole or a via hole.

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

9. A motor formed by providing one of the motor coil substrate and the magnet according to claim 8 on a rotor and the other on a stator.

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