Flexible circuit board, electric motor, and method for manufacturing a flexible circuit board

Abstract

To provide a flexible circuit board that can achieve a reduction in the weight of an electric motor and simplification of manufacturing processes, and a method for manufacturing the same.SOLUTION: A flexible circuit board 1 comprises: a plurality of pieces of first wiring U1 and third wiring U3 that are formed alternately and in parallel to each other on a first surface 2 of an insulating sheet 10; a plurality of pieces of second wiring U2 and fourth wiring U4 that are formed alternately and in parallel to each other on a second surface 3 of the insulating sheet 10; first continuous wiring Us1 that connects the ends of the adjacent first wiring U1 and second wiring U2 with the insulating sheet 10 therebetween; and a wiring connection part that forms second continuous wiring Us2 that connects the ends of the adjacent third wiring U3 and fourth wiring U4 with the insulating sheet 10 therebetween. The first continuous wiring Us1 and second continuous wiring Us2 have an intersection part a where they intersect each other with the insulating sheet 10 therebetween, and the intersection part a forms a coil.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a flexible circuit board, an electric motor, and a method for manufacturing a flexible circuit board.

Background Art

[0002] Conventionally, a technique for configuring a stator of a motor with a flexible circuit board has been known (for example, see Patent Document 1). Patent Document 1 discloses a manufacturing method in which a plurality of sheet coils each having a coil formed around each hole are wound in a spiral shape on a strip-shaped insulating film provided with a plurality of holes into which a stator core is inserted, and corresponding coils between the sheet coils are electrically connected to form a stator. In addition, bending portions are set at equal intervals on an insulating sheet, and department alternate semi-arc-shaped conductive patterns are formed on each unit piece partitioned by the bending, and are separated at the bending portions according to the number of turns so as to be usable. Such a configuration is known (for example, see Patent Document 2). In addition, an insulating layer, a first helical coil portion, a second helical coil portion, and a closed magnetic path are formed on a silicon substrate by a thin film forming technique, and the whole has a rectangular parallelepiped outer shape. A choke coil is known in which the first and second helical coil portions are formed such that the helical axes are substantially parallel to the substrate surface of the silicon substrate (for example, see Patent Document 3). In addition, parallel conductor line groups are formed on one side of a flexible substrate, and two substrates having metal conductor protrusion row groups exposed at both ends of each parallel conductor line group are overlapped in opposite directions, and after joining the opposing metal conductor protrusion row groups, a coreless motor using an armature wound in a cylindrical shape is known (for example, see Patent Document 4).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

[0004] While electric motors are required to be small and lightweight, the stator, a key component of electric motors, typically has a high-density coil winding configuration, which contributes to the motor's weight. Therefore, it is effective to reduce the weight of the electric motor by forming the coil pattern on a relatively lightweight flexible circuit board and constructing the stator from there. However, conventional stator configurations using flexible circuit boards have drawbacks, such as the need for processes to connect each coil formed on the flexible circuit board and to stack multiple flexible circuit boards with coil patterns formed on them, which complicates the manufacturing process and the structure of the stator. This application was filed in view of the above background, and aims to provide a flexible circuit board that enables weight reduction and simplification of the manufacturing process of electric motors, a method for manufacturing the same, and an electric motor composed of the flexible circuit board. [Means for solving the problem]

[0005] As a first embodiment for achieving the above objective, the insulating sheet has a flexible strip-shaped insulating sheet, on its first surface, a plurality of first and third wirings formed alternately in parallel in the longitudinal direction of the insulating sheet; on its second surface, a plurality of second and fourth wirings formed alternately in parallel in the longitudinal direction of the insulating sheet, offset from the first and third wirings; and a wiring connection portion which connects the ends of adjacent first and second wirings via the insulating sheet to form a first continuous wiring in which a plurality of first and second wirings are alternately connected via the insulating sheet, and connects the ends of adjacent third and fourth wirings via the insulating sheet to form a second continuous wiring in which a plurality of third and fourth wirings are alternately connected via the insulating sheet, wherein the first continuous wiring and the second continuous wiring have an intersection portion which intersects via the insulating sheet. hand The intersection forms a coil. Furthermore, one end of the insulating sheet of the first continuous wiring and the second continuous wiring in the longitudinal direction is connected by a reversal portion located at one end of the insulating sheet in the short direction, and the other end of the insulating sheet of the first continuous wiring and the second continuous wiring in the longitudinal direction is located at the one end of the insulating sheet in the short direction. Flexible circuit boards are one example.

[0006] In the flexible circuit board described above, the first continuous wiring and the second continuous wiring may be configured to be in a straight line shape, facing each other in parallel with respect to the insulating sheet at the intersection.

[0007] In the flexible circuit board described above, the first continuous wiring and the second continuous wiring may be configured to intersect in a chain-like manner via the insulating sheet.

[0008] In the flexible circuit board described above, the wiring connection portion may be configured to connect the terminals of adjacent first and second wirings, and the terminals of adjacent third and fourth wirings, through via holes that penetrate the insulating sheet.

[0009] As a second embodiment for achieving the above objective, an electric motor comprising a stator formed by bending a flexible circuit board on which electromagnetic coil wiring is formed into a cylindrical shape, and a rotor disposed on the outer or inner circumference of the stator, wherein the flexible circuit board has a plurality of first and third wirings formed alternately in parallel in the longitudinal direction of the insulating sheet on the first surface of a flexible strip-shaped insulating sheet, a plurality of second and fourth wirings formed alternately in parallel in the longitudinal direction of the insulating sheet on the second surface of the insulating sheet, offset from the first and third wirings, and a wiring connection portion which connects the ends of adjacent first and second wirings via the insulating sheet to form a first continuous wiring in which a plurality of first and second wirings are alternately connected via the insulating sheet, and connects the ends of adjacent third and fourth wirings via the insulating sheet to form a second continuous wiring in which a plurality of third and fourth wirings are alternately connected via the insulating sheet, and the first continuous wiring and the second continuous wiring have an intersection portion which intersects via the insulating sheet hand The intersection forms a coil. Furthermore, one end of the insulating sheet of the first continuous wiring and the second continuous wiring in the longitudinal direction is connected by a reversal portion located at one end of the insulating sheet in the short direction, and the other end of the insulating sheet of the first continuous wiring and the second continuous wiring is located at the one end of the insulating sheet in the short direction. An example is an electric motor with multiple phases.

[0010] As a third embodiment for achieving the above objective, the process involves: forming a plurality of first and third wirings alternately in parallel in a predetermined direction on the first surface of a flexible insulating sheet; forming a plurality of second and fourth wirings alternately in parallel in the predetermined direction of the insulating sheet on the second surface of the insulating sheet, offset from the first and third wirings; and forming a first continuous wiring in which a plurality of first and second wirings are alternately connected via the insulating sheet by connecting the ends of adjacent first and second wirings via the insulating sheet, and forming a second continuous wiring in which a plurality of third and fourth wirings are alternately connected via the insulating sheet by connecting the ends of adjacent third and fourth wirings via the insulating sheet. The process includes the steps of forming wiring and forming an electromagnetic coil at the intersection of the first continuous wiring and the second continuous wiring via the insulating sheet, and after the completion of the step of forming the intersection as an electromagnetic coil, cutting out the outer shape of a strip-shaped flexible circuit board from the insulating sheet with the predetermined direction in which the electromagnetic coil is formed as the longitudinal direction, wherein the step of forming the intersection as an electromagnetic coil includes the steps of forming a reversal portion at the location of the insulating sheet that is one end of the flexible circuit board in the short direction, connecting one end of the first continuous wiring and the second continuous wiring in the predetermined direction, and connecting the other end of the first continuous wiring and the second continuous wiring in the predetermined direction to the flexible circuit board. substrate A method for manufacturing a flexible circuit board includes the step of forming a coating on the portion of the insulating sheet that is one end of the short side of the flexible circuit board. [Effects of the Invention]

[0011] The above-mentioned flexible circuit board makes it possible to reduce the weight of electric motors and simplify the manufacturing process. [Brief explanation of the drawing]

[0012] [Figure 1] Figure 1 is an explanatory diagram showing the configuration of the flexible circuit board that makes up the stator of an electric motor. [Figure 2] FIG. 2 is an explanatory view of an electric motor provided with a stator using a flexible printed circuit board. [Figure 3] FIG. 3 is an explanatory view showing a configuration of a flexible printed circuit board in which wiring for forming an electromagnetic coil is doubled. [Figure 4] It is an explanatory view of the manufacturing process of a flexible printed circuit board. [Embodiment for Carrying Out the Invention]

[0013] [1. Configuration of Flexible Printed Circuit Board] Referring to FIGS. 1 and 2, the configuration of the flexible printed circuit board 1 of the present embodiment will be described. The flexible printed circuit board 1 is used as a component of the stator 70 of a three-phase brushless motor 50 (corresponding to the electric motor of the present disclosure) shown in FIG. 2. As shown in FIG. 1, the flexible printed circuit board 1 is formed by forming wiring of electromagnetic coils constituting slots for three phases of U, V, and W on both surfaces (first surface 2 and second surface 3) of an insulating sheet 10 having flexibility.

[0014] As shown in FIG. 2, by using a stator 70 in which the flexible printed circuit board 1 is bent into a cylindrical shape around the outer periphery of a rotor 60 to which a permanent magnet 61 is attached or embedded, it is possible to reduce the weight of the stator compared to a configuration in which a coil is formed by winding a conducting wire like a general stator. Note that the stator 70 may be arranged on the inner peripheral side of the rotor 60.

[0015] Further, according to the flexible printed circuit board 1, it is easy to increase the arrangement density of the slots S of the stator 70. By increasing the arrangement density of the slots S, the magnetic path of the magnetic force generated in the electromagnetic coil of each slot S can be shortened, and the metal portion 51 of the stator 70 can be made thinner. Thereby, per volume of the brushless motor 50 weight can be reduced.

[0016] Referring to Figure 1, on the first surface 2 of the insulating sheet 10, a plurality of first wirings U1 (U1a, U1b, U1c, U1d) for forming a U-phase electromagnetic coil are formed in parallel and continuously in the X direction, which is the longitudinal direction of the insulating sheet 10. Also, on the second surface 3 of the insulating sheet 10, a plurality of second wirings U2 (U2a, U2b, U2c, U2d) for forming a U-phase electromagnetic coil are formed in parallel in the X direction of the insulating sheet 10.

[0017] The ends of adjacent first wiring U1 and second wiring U2 are electrically connected via via holes h through the insulating sheet 10. As a result, a first continuous wiring Us1 is formed in which the first wiring U1 and second wiring U2 are alternately connected through the insulating sheet 10 in the order of first wiring U1a → second wiring U2a → first wiring U1b → second wiring U2b → first wiring U1c → second wiring U2c → first wiring U1d → second wiring U2d.

[0018] Furthermore, on the first surface 2 of the insulating sheet 10, a plurality of third wirings U3 (U3a, U3b, U3c, U3d) for forming a U-phase electromagnetic coil are formed in parallel and continuously in the X direction of the insulating sheet 10. Also, on the second surface 3 of the insulating sheet 10, a plurality of fourth wirings U4 (U4a, U4b, U4c, U4d) for forming a U-phase electromagnetic coil are formed in parallel and continuously in the X direction of the insulating sheet 10.

[0019] The ends of the adjacent third wiring U3 and fourth wiring U4 are electrically connected via via holes h through the insulating sheet 10. As a result, a second continuous wiring Us2 is formed in which the third wiring U3 and the fourth wiring U4 are alternately connected through the insulating sheet 10 in the order of third wiring U3a → fourth wiring U4a → third wiring U3b → fourth wiring U4b → third wiring U3c → fourth wiring U4c → third wiring U3d → fourth wiring U4d.

[0020] One end of the first continuous wiring Us1 (the left end in Figure 1) is connected to the external terminal Uc of the U phase. The other end of the first continuous wiring Us1 (the right end in Figure 1) is connected to one end of the second continuous wiring Us2 (the right end in Figure 1) by an inversion section Ut, and is electrically connected. The other end of the second continuous wiring (the left end in Figure 1) is connected to a common connection section Cc. This connection forms a circuit that is electrically connected from the external terminal Uc → first continuous wiring Us1 → inversion section Ut → second continuous wiring Us2 → common connection section Cc.

[0021] The first continuous wiring Us1 and the second continuous wiring Us2 have a linear intersection a that faces each other in parallel via an insulating sheet 10. Having such a linear intersection a increases the magnetic force generated when the intersection a functions as an electromagnetic coil.

[0022] Similarly, for the V phase, a first continuous wiring Vs1 is formed by alternately connecting multiple first wirings V1 (V1a, V1b, V1c, V1d) and second wirings V2 (V2a, V2b, V2c, V2d) via an insulating sheet 10. Furthermore, a second continuous wiring Vs2 is formed by alternately connecting multiple third wirings V3 (V3a, V3b, V3c, V3d) and fourth wirings V4 (V4a, V4b, V4c, V4d) via an insulating sheet 10. Finally, a circuit is formed that conducts from the external terminal Vc → first continuous wiring Vs1 → inversion section Vt → second continuous wiring Vs2 → common connection section Cc.

[0023] Similarly, for the W phase, a first continuous wiring Ws1 is formed by alternately connecting multiple first wirings W1 (W1a, W1b, W1c, W1d) and second wirings W2 (W2a, W2b, W2c, W2d) via an insulating sheet 10. In addition, multiple third wirings W3 (W3a, W3b, W3c, W3d) and a fourth wiring W4 ( W 4a, W 4b, W 4c, W4d) is formed by alternately connecting the insulating sheet 10 to create a second continuous wiring Ws2. Then, a circuit is formed that is electrically connected from the external terminal Wc → first continuous wiring Ws1 → inversion section Wt → second continuous wiring W2s → common connection section Cc.

[0024] Thus, the flexible circuit board 1 has a chain-like intersecting circuit that constitutes electromagnetic coils for multiple slots for three phases U, V, and W. By supplying drive power from the motor drive circuit to the external terminals Uc, Vc, and Wc, a rotating magnetic field can be generated by the magnetic force generated in each slot.

[0025] In this case, unlike the stator of a typical brushless motor, the process of forming each slot with electromagnetic coils wound with conductive wires and the connection process to create electrical conductivity between the coils are unnecessary, thus simplifying the stator manufacturing process. Furthermore, it is possible to improve the manufacturing quality of the brushless motor by avoiding defects in the process of connecting the electromagnetic coils in each slot, which can cause defects in the brushless motor.

[0026] In Figure 1, an example is shown in which four first wirings U1, V1, W1 and four second wirings U2, V2, W2 are formed. However, the number of stator slots can be arbitrarily set by increasing or decreasing the number of first wirings U1, V1, W1 and second wirings U2, V2, W2. In addition, three or more pairs of first and second wirings corresponding to three or more phases may be formed.

[0027] [2. Configuration with double wiring] Next, referring to Figure 3, we will explain an example of a configuration in which the first continuous wiring Us1 and the second continuous wiring Us2 corresponding to the U phase are duplicated. In Figure 3, for the sake of explanation, only the wiring for the U phase is shown, but the wiring for the V phase and W phase are similar.

[0028] In the example shown in Figure 3, two first continuous wirings Us1 (Us11, Us12) and two second continuous wirings Us2 (Us21, Us22) are formed. The first continuous wiring Us11 is formed by alternately connecting a plurality of first wirings U11 (U11a, U11b, U11c, U11d) formed on the first surface 2 of the insulating sheet 10 and a plurality of second wirings U21 (U21a, U21b, U21c, U21d) formed on the second surface 3 of the insulating sheet via via holes h.

[0029] Furthermore, the first second continuous wiring Us21 is formed by alternately connecting a plurality of third wirings U31 (U31a, U31b, U31c, U31d) formed on the second surface 3 of the insulating sheet 10 and a plurality of fourth wirings U41 (U41a, U41b, U41c, U41d) formed on the first surface 2 of the insulating sheet 10 via via holes h through the insulating sheet 10.

[0030] The second first continuous wiring Us12 is formed by alternately connecting a plurality of first wirings U12 (U12a, U12b, U12c, U12d) formed on the first surface 2 of the insulating sheet 10 and a plurality of second wirings U22 (U22a, U22b, U22c, U22d) formed on the second surface 3 of the insulating sheet 10 via via holes h through the insulating sheet 10.

[0031] Furthermore, the second continuous wiring Us22 is formed by alternately connecting a plurality of third wirings U32 (U32a, U32b, U32c, U32d) formed on the second surface 3 of the insulating sheet 10 and a fourth wiring U42 (U42a, U42b, U42c, U42d) formed on the first surface 2 of the insulating sheet 10 via via holes h through the insulating sheet 10.

[0032] One end of the first continuous wiring Us11 (the left end in Figure 3) is connected to the external terminal Uc, and the other end of the first continuous wiring Us11 (the right end in Figure 3) and one end of the second continuous wiring Us21 (the right end in Figure 3) are connected by the inversion section Ut1. Also, one end of the first continuous wiring Us12 (the left end in Figure 3) is connected to the other end of the second continuous wiring Us21 (the left end in Figure 3) and the relay section Ur. Furthermore, the other end of the first continuous wiring Us12 (the right end in Figure 3) and one end of the second continuous wiring Us22 (the right end in Figure 3) are connected and electrically connected by the inversion section Ut2. In addition, the other end of the second continuous wiring Us22 (the left end in Figure 3) is connected to the common connection section Cc.

[0033] This forms a circuit that conducts from the external terminal Uc → first continuous wiring Us11 → inversion section Ut1 → second continuous wiring Us21 → relay section Ur → first continuous wiring Us12 → inversion section Ut2 → second continuous wiring Us22 → common connection section Cc. As described above, the intersection a of the first continuous wiring Us11 and the second continuous wiring Us21 is a straight line shape with parallel opposite lines separated by the insulating sheet 10. The same applies to the first continuous wiring Us12 and the second continuous wiring Us22. As shown by L in Figure 3, an electromagnetic coil is formed by double wiring at the intersection of the first continuous wiring Us11 and the second continuous wiring Us21, and at the intersection of the first continuous wiring Us12 and the second continuous wiring Us22.

[0034] In this way, by using double wiring, the magnetic force generated in the electromagnetic coils of the slots can be increased when the stator is constructed using the flexible circuit board 1. Note that the wiring may be tripled or more.

[0035] [3. Manufacturing of Flexible Circuit Boards] Referring to Figure 4, the manufacturing process of flexible circuit board 1 will be explained. The manufacturing process includes the following steps: (1) CCL (Cupper Clad Lamination, copper foil) preparation, (2) via hole drilling, (3) via plating, (4) dry film application, (5) exposure, (6) development, (7) etching, (8) dry film removal, (9) CL (Cover Lay) application and curing, (10) surface treatment, (11) outline cutting, and (12) inspection.

[0036] (1) CCL fabrication: Copper foils 12a and 12b are attached to both sides of the insulating sheet 10 (corresponding to the first side 2 and second side 3 in Figures 1 and 3) using adhesives 11a and 11b. (2) Via holes… Via holes 13a and 13b are made to allow electrical conductivity between copper foil 12a and copper foil 12b via the insulating sheet 10.

[0037] (3) Via plating: The via holes 13a, 13b and copper foils 12a, 12b are plated to make the copper foils 12a, 12b on both sides of the insulating sheet 10 electrically conductive. (4) Dry film application: Dry films 15a and 15b, which are made by processing photosensitive resin into a film, are applied to the first side 2 and the second side 3.

[0038] (5) Exposure... Negative films 16a and 16b with the circuit pattern drawn on them are placed on dry films 15a and 15b and exposed to ultraviolet light (UV) to harden the circuit parts. 17a to 17f are areas other than the circuit parts. In the example in Figure 1, the first wiring U1, V1, W1 and the fourth wiring U4, V4, W4 are drawn on the negative film 16b on the first side 2, and the second wiring U2, V2, W2 and the third wiring U3, V3, W3 are drawn on the negative film 16a on the second side 3.

[0039] (6) Development: Dissolve and remove the hardened portions of dry films 15a and 15b that correspond to areas other than the circuit pattern. (7) Etching... Dry etching using a reactive gas or plasma removes only the portions 19a to 19f from which the dry films 15a and 15b of the copper foils 12a and 12b and the plating 14a, 14b, and 14c have been removed.

[0040] (8) Dry film removal: Remove dry films 15a and 15b using a chemical solution. (9) CL bonding & curing... Coverlays 21a to 21d are pressed and bonded from the first surface 2 and second surface 3 sides to form an insulating layer. (10) Surface treatment: Gold plating is applied to the exposed parts of copper foil 12a and 12b (for rust prevention).

[0041] (11) Outline cutting...By cutting out the outline from the sheet, the flexible circuit board 1 shown in Figure 1 is completed. (12) Inspection... The flexible circuit board 1 is inspected for continuity, open circuits, short circuits, etc. In this case, the flexible circuit board 1 can be inspected on its own before being incorporated into the brushless motor 50. Therefore, unlike typical brushless motors in which the stator is assembled by incorporating electromagnetic coils wound with conductors, it is possible to avoid situations where faulty wiring in the stator is discovered during inspection after the brushless motor has been assembled, requiring replacement or repair of the stator.

[0042] [4. Other Embodiments] In the above embodiment, an example was shown in which the flexible circuit board 1 of this disclosure is used as a component of the stator of a brushless motor 50. However, the flexible circuit board 1 can also be used to configure the stator of other types of electric motors that use electromagnetic coils.

[0043] Furthermore, the flexible circuit board disclosed herein can be applied to applications other than electric motor stators. For example, the flexible circuit board disclosed herein may be used for noise suppression applications such as choke coils, rather than electromagnetic coils.

[0044] In the above embodiment, the intersection a of the first continuous wiring Us1 and the second continuous wiring Us2 is formed as a straight line, with the insulating sheet 10 in between, facing each other in parallel. However, the intersection a may be of other shapes, and in this case as well, an electromagnetic coil can be formed by the intersection a. The same applies to the intersection of the first continuous wiring Vs1 and the second continuous wiring Vs2, and the intersection of the first continuous wiring Ws1 and the second continuous wiring Ws2.

[0045] In the above embodiment, as shown in Figure 4, an example of manufacturing the flexible circuit board 1 by dry etching was described, but it may also be manufactured by wet etching. Furthermore, the flexible circuit board 1 may be manufactured using other manufacturing methods, such as an additive method in which copper is deposited only in the wiring portions by electroless plating, instead of a subtractive method by etching.

[0046] [5. Configurations supported by the above embodiment] The above embodiment is a specific example of the following configuration.

[0047] (Configuration 1) A flexible circuit board comprising: a first surface of a flexible strip-shaped insulating sheet having a plurality of first and third wirings formed alternately in parallel in the longitudinal direction of the insulating sheet; a second surface of the insulating sheet having a plurality of second and fourth wirings formed alternately in parallel in the longitudinal direction of the insulating sheet, offset from the first and third wirings; a wiring connection portion which connects the ends of adjacent first and second wirings via the insulating sheet to form a first continuous wiring in which a plurality of first and second wirings are alternately connected via the insulating sheet, and connects the ends of adjacent third and fourth wirings via the insulating sheet to form a second continuous wiring in which a plurality of third and fourth wirings are alternately connected via the insulating sheet; the first continuous wiring and the second continuous wiring have an intersection portion which crosses via the insulating sheet, and the intersection portion which forms a coil. In the flexible circuit board of Configuration 1, the connections of the first, second, third, and fourth wirings formed on the insulating sheet are completed by the wiring connection section. Furthermore, the coil specifications can be set by the shape of the intersection of the first continuous wiring and the second continuous wiring. Therefore, the manufacturing process can be simplified by eliminating the need for the process of adjusting the connection and coil specifications, and the circuit board is made lighter by increasing the density by wiring the coils on the insulating sheet. Thus, by constructing an electric motor using the flexible circuit board of Configuration 1, it is possible to make the electric motor lighter and simplify the manufacturing process.

[0048] (Configuration 2) The flexible circuit board according to Configuration 1, wherein the first continuous wiring and the second continuous wiring are in a linear shape, facing each other in parallel via the insulating sheet at the intersection. According to the flexible circuit board of configuration 2, the magnetic force generated by the coil can be increased by making the intersections linear in shape.

[0049] (Configuration 3) A flexible circuit board according to Configuration 1 or Configuration 2, wherein the first continuous wiring and the second continuous wiring are intersected in a chain-like manner via the insulating sheet. The flexible circuit board of configuration 3 allows for the creation of a flexible circuit board with an increased density of multiple intersections.

[0050] (Configuration 4) A flexible circuit board according to any one of Configurations 1 to 3, wherein the wiring connection portion connects the terminals of adjacent first and second wirings and the terminals of adjacent third and fourth wirings by via holes penetrating the insulating sheet. According to the flexible circuit board of configuration 4, by making connections using via holes, it becomes unnecessary to make separate connections between the terminals of the first and second wiring, and between the terminals of the third and fourth wiring, thereby simplifying the manufacturing of the flexible circuit board.

[0051] (Configuration 5) An electric motor having a stator formed by bending a flexible circuit board on which electromagnetic coil wiring is formed into a cylindrical shape, and a rotor arranged on the outer or inner circumference of the stator, wherein the flexible circuit board has a plurality of first and third wirings formed alternately in parallel in the longitudinal direction of the insulating sheet on the first surface of a flexible strip-shaped insulating sheet, a plurality of second and fourth wirings formed alternately in parallel in the longitudinal direction of the insulating sheet on the second surface of the insulating sheet, offset from the first and third wirings, and a wiring connection portion which connects the ends of adjacent first and second wirings via the insulating sheet to form a first continuous wiring in which a plurality of first and second wirings are alternately connected via the insulating sheet, and connects the ends of adjacent third and fourth wirings via the insulating sheet to form a second continuous wiring in which a plurality of third and fourth wirings are alternately connected via the insulating sheet, and the first continuous wiring and the second continuous wiring have an intersection portion which intersects via the insulating sheet, and the intersection portion which forms a coil, the configuration having a plurality of phases. According to the electric motor of configuration 5, since the stator circuit wiring is formed on the flexible circuit board, the process of constructing the stator by incorporating coils wound with conductors and the inspection of the assembled stator are eliminated, thereby simplifying the electric motor manufacturing process. Furthermore, by constructing the stator using a flexible circuit board, the electric motor can be made lighter.

[0052] (Configuration 6) Flexibility possessA method for manufacturing a flexible circuit board, comprising the steps of: forming a plurality of first and third wirings on a first surface of an insulating sheet, arranged alternately in parallel in a predetermined direction; forming a plurality of second and fourth wirings on a second surface of the insulating sheet, arranged alternately in parallel in the predetermined direction of the insulating sheet, offset from the first and third wirings; forming a first continuous wiring in which a plurality of first and second wirings are alternately connected via the insulating sheet by connecting the ends of adjacent first and second wirings via the insulating sheet, forming a second continuous wiring in which a plurality of third and fourth wirings are alternately connected via the insulating sheet, and forming an electromagnetic coil at the intersection of the first and second continuous wirings via the insulating sheet. By implementing the manufacturing method of configuration 6, the flexible circuit board of configuration 1 can be manufactured. [Explanation of Symbols]

[0053] 1... Flexible circuit board, 2... First side of insulating sheet, 3... Second side of insulating sheet, 10 insulating sheets, U1 (U1a~U1d)... First wiring of U phase, V1 (V1a~V1d)... First wiring of V phase, W1 (W1a~W1d)... First wiring of W phase, U2 (U2a~U2d)... Second wiring of U phase, V2 (V2a~V2d)... Second wiring of V phase, W2 (W2a~W2d)... Second wiring of W phase, U3 (U3a~U3d)... Third wiring of U phase, V3 ( V3a~V3d)...Third wiring of the V phase, W3(W3a~W3d)...Third wiring of the W phase, U4(U4a~U4d)...Fourth wiring of the U phase, Us1...First continuous wiring of the U phase, Vs1...First continuous wiring of the V phase, Ws1...First continuous wiring of the W phase, Us2...Second continuous wiring of the U phase, Vs2...Second continuous wiring of the V phase, Ws2...Second continuous wiring of the W phase, Ut...Inversion section of the U phase, Vt...Inversion section of the V phase, Wt...Inversion section of the W phase, Uc...External terminal of the U phase, Vc...External terminal of the V phase, Wc...External terminal of the W phase, Cc...Common connection section U11 (U11a~U11d), U12 (U12a~U12d)...Double first wiring of the U phase, U21 (U21a~U21d), U22 (U22a~U22d)...Double second wiring of the U phase, Us11, Us12...Double first continuous wiring of the U phase, Us21, Us22...Double second continuous wiring of the U phase, Ut1, Ut2...Double reversing section of the U phase, 50...Brushless motor (electric motor), 51...Metal part, 60...Rotor, 61...Permanent magnet, 70...Stator, a...Intersection, L...Electromagnetic coil section.

Claims

1. On the first surface of a flexible, strip-shaped insulating sheet, a plurality of first and third wirings are formed alternately in parallel in the longitudinal direction of the insulating sheet, On the second surface of the insulating sheet, a plurality of second and fourth wirings are formed alternately in parallel in the longitudinal direction of the insulating sheet, offset from the first and third wirings, The wiring connection section includes a wiring connection section which connects the ends of adjacent first and second wirings via the insulating sheet to form a first continuous wiring configuration in which a plurality of first and second wirings are alternately connected via the insulating sheet, and connects the ends of adjacent third and fourth wirings via the insulating sheet to form a second continuous wiring configuration in which a plurality of third and fourth wirings are alternately connected via the insulating sheet, The first continuous wiring and the second continuous wiring have an intersection where they cross via the insulating sheet, and the intersection forms a coil. One end of the insulating sheet of the first continuous wiring and the second continuous wiring in the longitudinal direction is connected by a reversal portion located at one end of the insulating sheet in the short direction, and the other end of the insulating sheet of the first continuous wiring and the second continuous wiring in the longitudinal direction is located at the one end of the insulating sheet in the short direction. Flexible circuit board.

2. The first continuous wiring and the second continuous wiring are in a straight line shape, facing each other parallel to each other at the intersection, separated by the insulating sheet. The flexible circuit board according to claim 1.

3. The first continuous wiring and the second continuous wiring have a chain-like shape, intersecting each other via the insulating sheet. A flexible circuit board according to claim 1 or claim 2.

4. The wiring connection section connects the terminals of adjacent first and second wirings, and the terminals of adjacent third and fourth wirings, through via holes that penetrate the insulating sheet. A flexible circuit board according to claim 1 or claim 2.

5. An electric motor comprising a stator formed by bending a flexible circuit board on which electromagnetic coil wiring is formed into a cylindrical shape, and a rotor arranged on the outer or inner circumference of the stator, The aforementioned flexible circuit board is On the first surface of a flexible, strip-shaped insulating sheet, a plurality of first and third wirings are formed alternately in parallel in the longitudinal direction of the insulating sheet, On the second surface of the insulating sheet, a plurality of second and fourth wirings are formed alternately in parallel in the longitudinal direction of the insulating sheet, offset from the first and third wirings, The wiring connection section includes a wiring connection section which connects the ends of adjacent first and second wirings via the insulating sheet to form a first continuous wiring configuration in which a plurality of first and second wirings are alternately connected via the insulating sheet, and connects the ends of adjacent third and fourth wirings via the insulating sheet to form a second continuous wiring configuration in which a plurality of third and fourth wirings are alternately connected via the insulating sheet, The first continuous wiring and the second continuous wiring have an intersection where they cross via the insulating sheet, and the intersection forms a coil. One end of the insulating sheet of the first continuous wiring and the second continuous wiring in the longitudinal direction is connected by a reversal portion located at one end of the insulating sheet in the short direction, and the other end of the insulating sheet of the first continuous wiring and the second continuous wiring is located at the one end of the insulating sheet in the short direction. The configuration has multiple phases. Electric motor.

6. A step of forming a plurality of first and third wirings on the first surface of a flexible insulating sheet, which are arranged alternately in parallel in a predetermined direction, A step of forming a plurality of second and fourth wirings on the second surface of the insulating sheet, alternately in parallel in the predetermined direction of the insulating sheet, offset from the first and third wirings, The process involves connecting the ends of adjacent first and second wirings via the insulating sheet to form a first continuous wiring in which a plurality of first and second wirings are alternately connected via the insulating sheet, and connecting the ends of adjacent third and fourth wirings via the insulating sheet to form a second continuous wiring in which a plurality of third and fourth wirings are alternately connected via the insulating sheet, and forming an electromagnetic coil at the intersection where the first and second continuous wirings intersect via the insulating sheet, The process includes, after the completion of the step of forming the intersection portion as an electromagnetic coil, cutting out the outer shape of a strip-shaped flexible circuit board from the insulating sheet, with the predetermined direction in which the electromagnetic coil was formed having its longitudinal direction, The step of forming the intersection as an electromagnetic coil includes the steps of forming a reversal portion in the flexible circuit board at the location of the insulating sheet that is one end of the flexible circuit board in the short direction, connecting one end of the first continuous wiring and the second continuous wiring in the predetermined direction, and forming the other end of the first continuous wiring and the second continuous wiring in the predetermined direction at the location of the insulating sheet that is one end of the flexible circuit board in the short direction. A method for manufacturing flexible circuit boards.

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