Coil boards and motor coil boards and motors

Abstract

To provide a coil substrate that can improve the adhesion between wiring closest to a winding end side and a flexible substrate.SOLUTION: A coil substrate 40 includes: a flexible substrate 43 having a first surface F and a second surface B; and a plurality of coils C formed on the flexible substrate 43. The flexible substrate 43 includes a first side 41 on one end side in a longitudinal direction and a second side 42 on the other end side in the longitudinal direction. The plurality of coils C are arranged substantially in a line from the first side 41 to the second side 42. Each of the plurality of coils C is formed by a central space S and wiring w surrounding the central space S. The wiring w forming the coil C includes first wiring w1 on the first surface F and second wiring w2 on the second surface B. The first wiring w1 closest to the second side 42 includes an R portion 44 forming a substantially arc-shaped outer edge.SELECTED DRAWING: Figure 3

Description

Technical Field

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

Background Art

[0002] Patent Document 1 discloses a coil substrate for a motor. As shown in FIG. 2(A) of Patent Document 1, the coil substrate for a motor of Patent Document 1 is formed by winding a coil substrate including a flexible substrate having a plurality of coils into a substantially cylindrical shape.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

[0004] <Problem of Patent Document 1> In the technique of Patent Document 1, a coil substrate for a motor is formed by winding a coil substrate including a flexible substrate having a plurality of coils into a substantially cylindrical shape. For this reason, it is conceivable that the wiring of the coil on the winding end side may peel off from the flexible substrate which is an insulating layer. In the coil substrate for a motor of Patent Document 1, it is conceivable that appearance defects, deterioration of reliability, and troubles in motor installation may occur due to the occurrence of peeling.

Means for Solving the Problem

[0005] The coil substrate of the present invention comprises a flexible substrate having a first surface and a second surface opposite to the first surface, and a plurality of coils formed on the flexible substrate, wherein the flexible substrate includes a first side on one end in the longitudinal direction and a second side on the other end in the longitudinal direction, the plurality of coils are arranged in substantially a straight line from the first side to the second side, each of the plurality of coils is formed by a central space and wiring surrounding the central space, the wiring forming the coil comprises a first wiring on the first surface and a second wiring on the second surface, the first wiring closest to the second side has an R portion forming a substantially arc-shaped outer edge.

[0006] <Effects of the Embodiment> In the coil substrate of the embodiment of the present invention, the motor coil substrate is formed by starting the winding from the first side on one end of the flexible substrate in the longitudinal direction. The second side on the other end in the longitudinal direction becomes the winding end side. In the coil substrate of the embodiment, the first wiring closest to the second side on the other end in the longitudinal direction is provided with an R-shaped section. The outer edge of the R-shaped section is substantially arc-shaped. The outer edge of the first wiring located closest to the winding end is substantially arc-shaped. Therefore, even when winding in a substantially cylindrical shape, the adhesion between the first wiring and the flexible substrate can be improved compared to cases where the outer edge of the first wiring is not substantially arc-shaped but has a pointed shape or substantially right-angle shape. In a motor coil substrate formed using the coil substrate of the embodiment, the occurrence of appearance defects and problems during motor installation can be suppressed, and reliability can be improved. [Brief explanation of the drawing]

[0007] [Figure 1] Figure 1(A) is a schematic diagram of the motor according to the embodiment, and Figure 1(B) is a schematic diagram of the motor coil board according to the embodiment. [Figure 2] This is a schematic diagram of the coil substrate of the embodiment. [Figure 3] This is a partially enlarged view showing a region near the through-hole of the coil located closest to the end of the winding process in the coil substrate of the embodiment. [Modes for carrying out the invention]

[0008] <Embodiment> As shown in Figure 1(A), the motor 10 has a motor coil substrate 20 and a magnet 30. An example of the motor 10 is a brushless motor. As shown in Figure 1(B), the motor coil substrate 20 is formed by winding a coil substrate 40 into a substantially cylindrical shape, with the first side 41 being the starting side and the second side 42 being the ending side, the first surface F being the outer circumference side and the second surface B being the inner circumference side. In the example in Figure 1(B), the motor coil substrate 20 is formed by winding the coil substrate 40 three times. Note that the number of turns of the coil substrate does not have to be three; it may be one turn or four or more turns.

[0009] As shown in Figure 2, the coil substrate 40 has a flexible substrate 43, a plurality of coils C, a plurality of terminals T, a plurality of first connecting wires L1, and a plurality of second connecting wires L2. The coil substrate 40 has a first turn portion P1, a second turn portion P2, and a third turn portion P3 along its longitudinal direction. When the coil substrate 40 is wound, as shown in Figure 1(B), each of the portions P1, P2, and P3 forms approximately one turn. The first turn portion P1 is wound on the innermost side, and the third turn portion P3 is wound on the outermost side. As shown in Figure 2, the coil substrate 40 has portions P4 and P5 along its short direction. A plurality of coils C are formed in portion P4, and a plurality of first connecting wires L1 and a plurality of second connecting wires L2 are formed in portion P5.

[0010] The flexible substrate 43 has a first side 41 on one end in the longitudinal direction and a second side 42 on the other end in the longitudinal direction. On the first surface F and the second surface B opposite the first surface of the flexible substrate 43, wiring w that forms the coil C and wiring w that forms the first connecting line L1 and the second connecting line L2 are formed. An example of the flexible substrate 43 is a substrate in which the surface of a thin polyimide substrate on which the wiring w is formed is covered with an insulating resin. In this embodiment, "adhesion between the first wiring and the flexible substrate" refers to the adhesion of the first wiring w1 to the substrate of the flexible substrate 43.

[0011] Multiple coils C are formed on a flexible substrate 43. The multiple coils C are arranged in a line along the winding direction WD from the first side 41 to the second side 42. The multiple coils C include U-phase coils CU1 to CU6, V-phase coils CV1 to CV6, and W-phase coils CW1 to CW6. Each of the multiple coils CU1 to CW6 is arranged such that the U-phase coil, V-phase coil, and W-phase coil partially overlap. The U-phase coils CU1 and CU2 in the first turn portion P1, the U-phase coils CU3 and CU4 in the second turn portion P2, and the U-phase coils CU5 and CU6 in the third turn portion P3 are arranged to overlap when the coil substrate 40 is wound, as shown in Figure 1(B). The V-phase coils CV1 and CV2 of the first turn P1, the V-phase coils CV3 and CV4 of the second turn P2, and the V-phase coils CV5 and CV6 of the third turn P3 are arranged to overlap when the coil substrate 40 is wound. The W-phase coils CW1 and CW2 of the first turn P1, the W-phase coils CW3 and CW4 of the second turn P2, and the W-phase coils CW5 and CW6 of the third turn P3 are arranged to overlap when the coil substrate 40 is wound.

[0012] The U-phase coils CU1, CU3, and CU5 have their wiring w wound counterclockwise when viewed from the outer periphery of the motor coil board 20. The U-phase coils CU2, CU4, and CU6 have their wiring w wound clockwise when viewed from the outer periphery of the motor coil board 20. The U-phase coils CU1, CU3, and CU5 are connected to the U-phase coils CU2, CU4, and CU6 by a second U-phase connecting wire L2U such that the direction of the current flowing through the U-phase coils CU1, CU3, and CU5 is opposite to the direction of the current flowing through the U-phase coils CU2, CU4, and CU6. The U-phase coils CU2, CU4 and U-phase coils CU3, CU5 are connected to the second U-phase connecting wire L2U such that the direction of the current flowing through the U-phase coils CU2, CU4 is opposite to the direction of the current flowing through the U-phase coils CU3, CU5. The V-phase coils CV1 to CV6 and the W-phase coils CW1 to CW6 are configured and connected in the same way as the U-phase coils CU1 to CU6.

[0013] Each of the multiple coils C is formed by a central space S and wiring w surrounding the central space S. Each turn of each coil C is formed by a first wiring w1 on the first side 41 of the flexible substrate 43 and a second wiring w2 on the second side 42. The first wiring w1 is formed on the first surface F of the flexible substrate 43, and the second wiring w2 is formed on the second surface B. The flexible substrate 43 has through-holes TH that penetrate the flexible substrate 43 at the ends of the first wiring w1 and the ends of the second wiring w2. The ends of the first wiring w1 and the ends of the second wiring w2 are connected by via wiring wb filled in the through-holes TH.

[0014] Multiple terminals T are connected to wiring w that forms multiple coils C. The multiple terminals T have terminals TU for the U phase, terminals TV for the V phase, and terminals TW for the W phase. By connecting each terminal T with external wiring, or by connecting it to another circuit board, it functions as a motor coil board 20.

[0015] Multiple first connection lines L1 connect the wiring w forming the coil C to the terminal T. The multiple first connection lines L1 include a U-phase first connection line L1U, a V-phase first connection line L1V, and a W-phase first connection line L1W. The U-phase first connection line L1U connects the U-phase terminal TU to the U-phase coil CU1. The V-phase first connection line L1V connects the V-phase terminal TV to the V-phase coil CV6. The W-phase first connection line L1W connects the W-phase terminal TW to the W-phase coil CW1. In the example in Figure 2, the U-phase first connection line L1U, the V-phase first connection line L1V, and the W-phase first connection line L1W are formed on the first surface F of the flexible substrate 43.

[0016] Multiple second connection lines L2 connect multiple coils C to each other. The multiple second connection lines L2 include a U-phase second connection line L2U, a V-phase second connection line L2V, and a W-phase second connection line L2W. The U-phase second connection line L2U connects U-phase coils CU1 and CU2 to each other, U-phase coils CU2 and CU3 to each other, U-phase coils CU3 and CU4 to each other, U-phase coils CU4 and CU5 to each other, and U-phase coils CU5 and CU6 to each other. The V-phase second connection line L2V connects V-phase coils CV1 and CV2 to each other, V-phase coils CV2 and CV3 to each other, V-phase coils CV3 and CV4 to each other, V-phase coils CV4 and CV5 to each other, and V-phase coils CV5 and CV6 to each other. The second W-phase connection line L2W connects W-phase coils CW1 and CW2 to each other, CW2 and CW3 to each other, CW3 and CW4 to each other, CW4 and CW5 to each other, and CW5 and CW6 to each other.

[0017] In the example shown in Figure 2, the second U-phase connecting wire L2U, which connects U-phase coils CU2 and CU3 to each other and U-phase coils CU4 and CU5 to each other, is formed on the first surface F of the flexible substrate 43. The second V-phase connecting wire L2V, which connects V-phase coils CV2 and CV3 to each other and V-phase coils CV4 and CV5 to each other, is also formed on the first surface F. The second W-phase connecting wire L2W, which connects W-phase coils CW2 and CW3 to each other and W-phase coils CW4 and CW5 to each other, is also formed on the first surface F. Any other second connecting wires L2 are formed on the second surface B of the flexible substrate 43.

[0018] The wiring w forming coil C and the wiring w forming the first and second connecting lines L1 and L2 are formed using printed circuit board technology. The wiring w is formed by plating. The wiring w is formed by etching copper foil. The wiring w may also be formed by a semi-additive method, an MSAP method, or a subtractive method.

[0019] FIG. 3 shows a partially enlarged view of region A in the vicinity of the through hole TH on one end side in the lateral direction of the coil substrate 40, for the coil CW6 located on the most winding end side of the coil substrate 40. In the example of FIG. 3, each through hole TH is formed by three through holes TH1, TH2, TH3. The three through holes TH1, TH2, TH3 are arranged in a substantially triangular shape, with the through hole TH1 arranged closest to the first side 41, and the through hole TH3 arranged closest to the second side 42. The via wiring wb filled in each of the through holes TH1, TH2, TH3 connects the end of the first wiring w1 formed on the first surface F and the end of the second wiring w2 formed on the second surface B.

[0020] As shown in FIG. 3, the first wiring w1 constituting the turn closest to the second side 42 in the coil CW6 is provided with an R portion 44 forming a substantially arc-shaped outer edge on one end side in the lateral direction of the coil substrate 40. The R portion 44 is formed at a position offset from the through hole TH, in a portion of the first wiring w1 near the through hole TH. The R portion 44 is formed on the second side 42 side relative to the through hole TH3 located closest to the second side 42 among the three through holes TH1, TH2, TH3 constituting the through hole TH. The arc center Ro of the substantially arc shape of the R portion 44 is located on the first side 41 side relative to the R portion 44.

[0021] The first wiring w1 constituting turns other than the turn closest to the second side 42 in the coil CW6 is provided with an R portion 46 forming a substantially arc-shaped outer edge on one end side in the lateral direction of the coil substrate 40. The radius r1 of the R portion 44 of the first wiring w1 constituting the turn closest to the second side 42 is larger than the radius r2 of the R portion 46 of the other first wirings w1. The radius r1 of the R portion 44 is set to be as large as possible within a range that does not interfere with the through hole TH3 located closest to the second side 42 among the three through holes TH1, TH2, TH3.

[0022] Region B in the vicinity of the through hole TH on the other end side in the lateral direction of the coil substrate 40 of the coil CW6 is also configured in the same manner as the above-described region A.

[0023] <Effects of Embodiment> In the coil substrate 40 of the embodiment, the motor coil substrate 20 is formed by starting winding from the first side 41 on one end side in the longitudinal direction of the flexible substrate 43. The second side 42 on the other end side in the longitudinal direction serves as the winding end side. In the coil substrate 40 of the embodiment, the R portion 44 is provided in the first wiring w1 closest to the second side 42 on the other end side in the longitudinal direction. The outer edge of the R portion 44 has a substantially arcuate shape. The outer edge of the first wiring w1 located closest to the winding end side has a substantially arcuate shape. Therefore, even when winding into a substantially cylindrical shape, the adhesion between the first wiring w1 and the flexible substrate 43 can be improved compared to the case where the outer edge of the first wiring w1 is not formed into a substantially arcuate shape but is formed into a sharp shape or a substantially right-angled shape. In the motor coil substrate 20 formed using the coil substrate 40 of the embodiment, occurrence of appearance defects and troubles during installation of the motor 10 can be suppressed, and reliability can be improved.

[0024] According to the coil substrate 40 of the embodiment, since the R portion 44 is provided at a position offset from the through hole TH, the via wiring vb filled in the through hole TH is left uncut. The connection between the first wiring w1 and the second wiring w2 by the via wiring vb in the through hole TH is reliably maintained.

[0025] According to the coil substrate 40 of the embodiment, the shape of the R portion 44 can be formed into a substantially arcuate shape that wraps around the through hole TH3. Since interference between the R portion 44 and the through hole TH3 can be prevented, favorable connection between the first wiring w1 and the second wiring w2 can be maintained.

[0026] According to the coil substrate 40 of the embodiment, the substantially arcuate shape of the R portion 44 can be formed as an arc with as large a radius as possible as long as it does not interfere with the through hole TH3. The adhesion between the first wiring w1 and the flexible substrate 43 can be maximized as much as possible. [Description of Reference Numerals]

[0027] 10: Motor 20: Coil substrate for motor 30: Magnet 40: Coil substrate 41: First side 42: Second side 43: Flexible circuit board 44 :R section B: 2nd side C: Coil F: 1st page Ro: Center of the arc S: Central space TH: Through-hole TH1: Through-hole TH2: Through-hole TH3: Through-hole w: wiring w1: First wiring w2: Second wiring wb: via wiring

Claims

1. A flexible substrate having a first surface and a second surface opposite to the first surface, The flexible substrate has a plurality of coils formed on it, The flexible substrate includes a first side on one end in the longitudinal direction and a second side on the other end in the longitudinal direction. The plurality of coils are arranged in a nearly straight line from the first side to the second side, Each of the aforementioned plurality of coils is formed by a central space and wiring surrounding the central space, The wiring forming the coil includes a first wiring on the first surface and a second wiring on the second surface. Each of the plurality of coils is a coil substrate having a plurality of turns formed by the first wiring and the second wiring, In the coil located closest to the second side among the plurality of coils, the first wiring constituting the turn closest to the second side has a first R portion forming a substantially arc-shaped outer edge on one end and the other end in the short-side direction of the flexible substrate, and the first wiring constituting turns other than the turn closest to the second side has a second R portion forming a substantially arc-shaped outer edge on one end and the other end in the short-side direction. The radius of the first R portion is larger than the radius of the second R portion.

2. A coil substrate according to claim 1, The flexible substrate has through holes, The aforementioned wiring includes via wiring that penetrates the through-hole and connects the first wiring and the second wiring. The first R portion is formed in the part of the first wiring that constitutes the turn closest to the second side, near the through-hole.

3. The coil substrate according to claim 2, wherein the first R portion is formed on the second side side of the through hole.

4. The coil substrate according to claim 3, wherein the center of the substantially arc shape of the first R portion is located on the first side side of the first R portion.

5. A motor coil substrate formed by winding a coil substrate according to any one of claims 1 to 4 in a substantially cylindrical shape, with the first side being the starting side and the second side being the ending side, the first surface being the outer circumference side and the second surface being the inner circumference side.

6. A motor comprising a motor coil board according to claim 5 and a magnet.

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