Motor stator module having printed circuit board-based wiring structure, motor including same, and method for manufacturing same

Abstract

A motor stator module according to an embodiment disclosed herein comprises: a plurality of individual coils; and a printed circuit board in which a plurality of bonding pads are formed so that terminals of each of the plurality of individual coils can be bonded thereto, and which includes a conductive pattern electrically connecting the plurality of bonding pads, wherein the terminals of the plurality of individual coils are bonded to the plurality of bonding pads, and the conductive pattern may be configured to electrically connect the plurality of individual coils to form at least one phase winding.

Description

A stator module for a motor having a printed circuit board-based wiring structure, a motor including the same, and a method for manufacturing the same.

[0001] The present invention relates to electric motor technology, and more specifically, to a stator module in which a plurality of individual coils are bonded to a printed circuit board (PCB) and a phase winding connection structure is formed using the conductive pattern of the printed circuit board.

[0002] As applications requiring high power, high torque, and high efficiency (e.g., electric drives, robotics, aviation / drones, industrial drives, etc.) expand, there is a continuous demand for higher power density and system integration of motors. In response to these demands, active efforts are being made to optimize the winding structure of stators and increase the automation of manufacturing processes.

[0003] However, conventional motor stators often involved complex processes, such as lead wire wiring, busbars, end-winding section formation, and manual wiring, to implement electrical connections (series / parallel, star / delta, etc.) between multiple coils. Particularly in coreless structures or high-current winding structures for high-output driving, issues regarding space, heat, vibration, and reliability at the connection points between coil terminals (end-winding / connection sections) can act as bottlenecks in design and manufacturing.

[0004] Furthermore, if a design is applied where the coil winding direction varies by slot or position, the winding process becomes complex and may require dedicated winding equipment. Additionally, managing the connection relationships (polarity / current direction) between coils becomes difficult, which can lead to increased assembly defects or quality variations. Moreover, if sensors (temperature / encoders, etc.), heat dissipation structures, or housing structures are added as separate components, the number of parts and assembly processes increases, potentially imposing limitations on modularization and automation.

[0005] Therefore, there is a need for technology that improves the manufacturability and reliability of stator modules by standardizing the manufacturing and management of individual coils, simplifying the connection structure between coils and facilitating design changes, and integrating bonding, wiring, sensors, heat dissipation, and housing.

[0006] Korean registered patent No. 0682808 (February 8, 2007) discloses a method for producing a multilayer circuit board.

[0007] The present disclosure was devised to solve the problems of the prior art as described above, and aims to provide a stator module for a motor and a method for manufacturing the same, which dramatically improves productivity by introducing a method of surface mounting a plurality of individual coils on a printed circuit board (PCB) and replacing the complex manual end-winding process with a conductive pattern inside the PCB.

[0008] In particular, the present disclosure aims to provide a technical structure that simplifies / automates the coil production process by winding all individual coils in the same rotational direction, while enabling normal motor operation by electrically reversing the current direction between adjacent coils through the wiring pattern of the PCB.

[0009] Furthermore, another objective of the present disclosure is to reduce the number of components and achieve miniaturization and weight reduction of the motor by utilizing the printed circuit board itself as a structural housing for the stator, a heat dissipation path, and a mounting platform for temperature / position sensors.

[0010] A stator module for a motor is disclosed according to one embodiment of the present disclosure for realizing the aforementioned problem. The stator module for a motor comprises: a plurality of individual coils; and a printed circuit board having a plurality of bonding pads formed so that the terminals of each of the plurality of individual coils can be bonded, and a conductive pattern that electrically connects the plurality of bonding pads, wherein the terminals of the plurality of individual coils are bonded to the plurality of bonding pads, and the conductive pattern may be configured to electrically connect the plurality of individual coils to form at least one phase winding.

[0011] In one embodiment, each of the plurality of individual coils may be formed by winding a flat wire.

[0012] In one embodiment, the plurality of individual coils may be wound in the same rotational direction.

[0013] In one embodiment, the conductive pattern of the printed circuit board may include an alternating connection wiring structure that connects the current application directions between the plurality of adjacent individual coils by reversing them.

[0014] In one embodiment, the plurality of individual coils may be formed to have a spiral or helical winding.

[0015] In one embodiment, the printed circuit board may include a positioning structure including a guide groove or a mounting alignment mark for arranging the plurality of individual coils.

[0016] In one embodiment, the terminals of the plurality of individual coils may be configured to be bonded to the plurality of bonding pads in a surface-mount manner.

[0017] In one embodiment, the joining of the terminals and the plurality of bonding pads can be performed by at least one method of soldering or welding.

[0018] In one embodiment, the printed circuit board is a multilayer printed circuit board comprising a plurality of layers, and the conductive pattern includes an end-winding connection portion that electrically connects the terminals of the plurality of individual coils, and may be formed to implement at least one of a series connection, a parallel connection, a star connection, and a delta connection between the plurality of individual coils.

[0019] In one embodiment, the printed circuit board may further include a common connection area for connecting some of the terminals of the plurality of individual coils in common.

[0020] In one embodiment, the printed circuit board may be configured such that a metal frame or reinforcing plate is integrally coupled to the outer periphery, so that the printed circuit board functions as at least a part of the housing of the stator module.

[0021] In one embodiment, the printed circuit board includes a temperature sensor for monitoring the temperature of at least some of the plurality of individual coils, and the temperature sensor may be disposed within a layer of the printed circuit board or mounted on the printed circuit board.

[0022] In one embodiment, the conduction pattern may include a pattern for forming a phase winding and a pattern including an encoder signal line.

[0023] In one embodiment, the printed circuit board may further include at least one of a pressure sensor or a vibration sensor for motor condition diagnosis.

[0024] In one embodiment, the printed circuit board includes a heat dissipation passage or heat dissipation channel for discharging heat generated from the plurality of individual coils to the outside, and the printed circuit board may be formed of a metal core printed circuit board (Metal Core PCB) or may include a thermally conductive resin.

[0025] In one embodiment, the stator module may have a coreless structure that does not include an iron core.

[0026] According to one embodiment of the present disclosure for realizing the above-described problem, a motor is disclosed. The motor comprises a stator module; and one or more rotors axially opposite to the stator module, wherein the stator module comprises a plurality of individual coils; and a printed circuit board comprising a plurality of junction pads formed so that the terminals of each of the plurality of individual coils can be joined, and a conductive pattern that electrically connects the plurality of junction pads, wherein the terminals of the plurality of individual coils are joined to the plurality of junction pads, and the conductive pattern may be configured to electrically connect the plurality of individual coils to form at least one phase winding.

[0027] According to one embodiment of the present disclosure for realizing the above-described problem, a method for manufacturing a motor is disclosed. The manufacturing method comprises the steps of: winding a conductive conductor to form a plurality of individual coils; preparing a printed circuit board comprising a plurality of bonding pads and a conductive pattern that electrically connects the plurality of bonding pads; arranging terminals of the plurality of individual coils on the plurality of bonding pads and bonding the terminals and the bonding pads to form a stator module; and coupling one or more rotors so as to be axially opposed to the stator module, wherein the conductive pattern may be configured to electrically connect the plurality of individual coils to form at least one phase winding.

[0028] According to the present disclosure, the mass production capability of a motor can be dramatically improved through an innovative stator structure that combines individual coils and a printed circuit board.

[0029] Specifically, even if multiple individual coils are simply manufactured to have the same rotational direction, a magnetic field / pole can be electrically formed through an alternating connection wiring structure formed on a printed circuit board, thus enabling mass production of coils using a general-purpose high-speed winding machine.

[0030] In addition, by replacing complex and bulky mechanical end-winding connections with slim multi-layer wiring patterns inside the printed circuit board, the volume and weight of the stator can be significantly reduced, and the reliability of the product can be enhanced by fundamentally eliminating the possibility of wiring defects caused by manual work.

[0031] Furthermore, by integrating a metal reinforcement plate into the printed circuit board to perform a housing function, applying a metal core PCB to improve heat dissipation performance, and integrating the wiring of temperature and encoder sensors within the board, it is possible to achieve component integration and optimized design for the entire motor system.

[0032] Meanwhile, the effects of the present disclosure are not limited to those mentioned above, and various effects may be included within the scope obvious to a person skilled in the art from the contents described below.

[0033] FIG. 1 is a schematic diagram showing the winding shape of a single coil according to one embodiment of the present disclosure.

[0034] FIG. 2 is a schematic diagram showing a state in which a plurality of individual coils are mounted on a printed circuit board according to one embodiment of the present disclosure.

[0035] FIG. 3 is a schematic diagram showing a connection or wiring structure inside a printed circuit board according to one embodiment of the present disclosure.

[0036] FIG. 4 is another diagram schematically showing a housing and heat dissipation channel structure integrated with a printed circuit board according to one embodiment of the present disclosure.

[0037] FIG. 5 is a schematic diagram showing a state in which a sensor is embedded in a printed circuit board according to one embodiment of the present disclosure.

[0038] Various embodiments are now described with reference to the drawings. In this specification, various descriptions are provided to provide an understanding of the present disclosure. However, it is evident that these embodiments can be practiced without such specific descriptions.

[0039] Furthermore, the term "or" is intended to mean an implicit "or" rather than an exclusive "or." That is, unless otherwise specified or evident from the context, "X uses A or B" is intended to mean one of the natural implicit substitutions. In other words, if X uses A; if X uses B; or if X uses both A and B, "X uses A or B" may apply to any of these cases. Additionally, the term "and / or" as used herein should be understood to refer to and include all possible combinations of one or more of the enumerated related items.

[0040] Additionally, the terms “comprising” and / or “comprising” should be understood to mean that such features and / or components are present. However, the terms “comprising” and / or “comprising” should be understood not to exclude the presence or addition of one or more other features, components and / or groups thereof. Furthermore, unless otherwise specified or clearly evident from the context to indicate a singular form, the singular in this specification and claims should generally be interpreted to mean “one or more.”

[0041] And, the term "at least one of A or B" should be interpreted to mean "a case including only A," "a case including only B," or "a combination of A and B."

[0042] Those skilled in the art should recognize that the various exemplary logical blocks, configurations, modules, circuits, means, logics, and algorithmic steps described in connection with the embodiments disclosed herein may be implemented in electronic hardware, computer software, or a combination of both. To clearly exemplify the interchangeability of hardware and software, various exemplary components, blocks, configurations, means, logics, modules, circuits, and steps have been generally described above in terms of their functionality. Whether such functionality is implemented in hardware or software depends on the specific application and design constraints imposed on the overall system. Skilled technicians may implement the described functionality in various ways for each specific application. However, such decisions regarding implementation should not be construed as going beyond the scope of this disclosure.

[0043] The description of the presented embodiments is provided to enable those skilled in the art to use or practice the present invention. Various modifications to these embodiments will be apparent to those skilled in the art. The general principles defined herein may be applied to other embodiments without departing from the scope of the present disclosure. Thus, the present invention is not limited to the embodiments presented herein. The present invention should be interpreted in the broadest possible scope consistent with the principles and novel features presented herein.

[0044]

[0045] In one embodiment, the present invention can be utilized as a technology applied to a motor in which a magnetic flux path is formed in the direction of the rotation axis. Not limited thereto, the individual coil-PCB connection platform structure of the present disclosure can be applied to various motor structures. In particular, the present invention focuses on a new configuration and manufacturing method of a stator that structurally and electrically integrates a plurality of independent coils regardless of the presence or absence of a core.

[0046] A motor according to one embodiment of the present invention may include a stator module (100) that generates a rotating magnetic field and a rotor (200) that rotates by being positioned opposite the stator module (100) with a predetermined air gap in the axial direction. The rotor (200) may have a structure in which a plurality of permanent magnets are arranged on a surface facing the stator module (100), and may be a double rotor type positioned on each side of the stator module (100), or a single rotor type positioned on only one side.

[0047] A stator module (100), which is a core component of the present invention, refers to a module configured to perform the stator function of a motor and may include at least a plurality of individual coils (110) and a printed circuit board (140) for electrically connecting them. The stator module (100) may be in the form of an independent module mounted within a motor housing, or it may be in the form of being formed integrally with a part of the motor's structure (e.g., housing, heat dissipation structure).

[0048] According to one embodiment of the present invention, a plurality of bonding pads (120) and a conductive pattern (130) may be formed on a printed circuit board (140).

[0049] A plurality of bonding pads (120) may be arranged so that the terminals (110-1) of each of the plurality of individual coils (110) can be bonded. For example, the first terminal (111-1) and the second terminal (111-2) of the first individual coil (111) may be bonded to the corresponding bonding pad (120), and the first terminal (112-1) and the second terminal (112-2) of the second individual coil (112) may also be bonded to the corresponding bonding pad (120). At this time, the correspondence is not limited to a 1:1 matching, and a structure in which one terminal is connected to a plurality of pads, or a plurality of terminals are connected to a common pad or a common connection area, is also possible.

[0050] The conductive pattern (130) can be configured to electrically connect the bonding pads (120) and further electrically connect a plurality of individual coils (110) to form at least one phase winding. That is, the main technical concept of the stator module (100) in the present invention includes structurally implementing the coil connection (series / parallel / star / delta, etc.) by designing / forming the conductive pattern (130) on the printed circuit board (140) without relying on separate lead wire work or busbar manual work.

[0051] In one embodiment, the stator module (100) may have a coreless structure that does not include an iron core. A coreless structure may be advantageous for reducing iron loss, reducing weight, and specific driving characteristics (such as responsiveness). However, the implementation form of the coreless structure may vary, and various modified embodiments are possible through the arrangement method of individual coils (110) (circular arrangement, polygonal arrangement, divided segment arrangement, etc.), reinforcing structure (frame / reinforcement plate), heat dissipation structure (MCPCB, thermally conductive resin), and connection topology (series / parallel / star / delta).

[0052]

[0053] The key terms used in this invention may be used exemplarily with the following meanings.

[0054] A unit coil (110) refers to a unit coil prepared in multiple numbers to form the phase winding of a motor. The unit coils (110) may be standardized with the same shape / specifications, or may have some different shapes depending on the target specifications (voltage / current / torque / space).

[0055] A terminal (110-1) refers to an area where the conductor of a single coil (110) is exposed or a connection structure is provided so as to be electrically connected to the outside. For example, a first single coil (111) may include a first terminal (111-1) and a second terminal (111-2), and a second single coil (112) may include a first terminal (112-1) and a second terminal (112-2). The terminal may be an exposed part of the conductor itself, or it may be in the form of a tab, lug, conductive pad, or plate attached to the conductor, but is not limited thereto.

[0056] A bond may refer to an electrical or mechanical connection between a terminal (110-1) and a bonding pad (120), and may include various conventional connection processes such as soldering, welding, brazing, conductive adhesive, press-fit / clinch bonding, and riveting. In one embodiment, the bonding is exemplified by a surface mount method and soldering / welding; however, since the purpose of the present invention is to implement a printed circuit board (PCB)-based connection through coil terminal-substrate pad bonding, the bonding method is not limited thereto.

[0057] A conductive pattern (130) refers to a conductive wiring / pattern formed on a printed circuit board (140) to allow current to flow. The conductive pattern (130) may be formed on a single layer or on multiple layers in a multilayer structure, and electrical connections between layers may be provided through vias, side conductive parts, or through conductive parts. The conductive pattern (130) may include a pattern for forming a phase winding, as well as a pattern for transmitting a sensor signal (e.g., an encoder signal line).

[0058] A phase winding refers to a group of windings formed by electrically connecting a plurality of individual coils (110). One or more phase windings may be formed depending on the driving method of the motor, such as single-phase, two-phase, or three-phase. In the present disclosure, at least one phase winding means that at least one group of windings is formed, and the number of phases or the connection topology are not limited thereto.

[0059] The alternating connection wiring structure refers to a wiring structure in which terminal connection relationships are set so that the direction of current application between adjacent individual coils is alternate (inverted from each other). This can function as a structural means to enable the direction of current application (polarity) to be controlled through the design of the conductive pattern (130) of the printed circuit board (140), even if the individual coils are manufactured with standardized winding directions.

[0060] A common connection area refers to an area for connecting some of a plurality of terminals to a common node. The common connection area may be used, for example, as a star point in a star connection or as a common bus node in a parallel connection, but is not limited thereto.

[0061] Coreless means a structure in which the stator module (100) does not include an iron core (magnetic core). However, even in a coreless structure, some non-magnetic / magnetic members for mechanical support, heat dissipation, shielding, or magnetic flux path control may be included, and the meaning of an iron core can be interpreted as a laminated iron core or a magnetic core equivalent thereto that is placed within the winding to form a main magnetic flux path.

[0062] Unlike a typical via that penetrates the interior of a printed circuit board (multilayer board), the lateral conductive portion is formed to extend along the side of the multilayer board in the thickness direction of the board (i.e., the stacking direction). This lateral conductive portion (130) can serve as a medium to electrically connect conductive patterns located on different layers (e.g., a first layer and a second layer) to form the entire coil circuit in series or in parallel. For example, the lateral conductive portion of the present invention can be directly and physically coupled to the end of a conductive pattern exposed on the side cut surface of the multilayer board. Since this lateral conductive portion utilizes the edge of the board, the coil density in the central part of the board can be maximized.

[0063] Via holes used for interlayer connections in general multilayer PCBs (Printed Circuit Boards) have limited hole sizes due to the limitations of the drilling process and thin plating thickness, which has the disadvantage of high resistance and excessive heat generation when used for motor driving that requires high current flow.

[0064] In contrast, the lateral conductive portion according to an embodiment of the present invention can form a direct electrical connection with the end of the coil pattern portion exposed on the lateral cut surface of a multilayer substrate. For example, the lateral conductive portion can form a conductive layer by widely utilizing the entire or a portion of the lateral side of the substrate. For instance, the lateral conductive portion forms a surface contact or a line contact covering the entire lateral side, rather than a point contact. Since this provides a current-carrying cross-sectional area several to tens of times larger than that of a via hole, it can drastically reduce resistance loss and heat generation during motor operation. Since this provides a significantly larger current-carrying cross-sectional area compared to a via hole with a limited diameter, it has the effect of drastically lowering electrical resistance and increasing allowable current capacity.

[0065] Furthermore, lateral conductive sections can be specifically implemented through edge plating technology. This method involves plating a conductive metal onto the sides of a substrate to create interlayer connection pathways. Since this method wraps the sides of the substrate with a smooth conductor, it can serve not only as an interlayer connection but also as a heat sink by expanding the heat dissipation surface area. Additionally, a shielding effect to block electromagnetic interference can be expected.

[0066] Alternatively, as another example, a method of forming grooves, such as semicircles, on the side of the substrate and filling the interior of these grooves with soldering or conductive paste to form a joint can also be utilized for implementing side conductive parts. This structure offers excellent mechanical bonding strength, ensuring connection reliability in motor driving environments with severe vibration. In particular, it acts as a guide during the vertical connection of multiple stacked stator modules, thereby enhancing assembly precision.

[0067]

[0068] Hereinafter, various embodiments of the present invention will be described in detail with reference to the drawings.

[0069] FIG. 1 is a schematic diagram showing the winding shape of an individual coil according to one embodiment of the present disclosure, and FIG. 2 is a schematic diagram showing the state in which a plurality of individual coils are mounted on a printed circuit board according to one embodiment of the present disclosure.

[0070] In one embodiment of the present disclosure, the stator module (100), which is a core component of the present invention, is largely composed of a combination of a plurality of individual coils (110) and a printed circuit board (140) that serves as a platform on which they are mounted and electrically connected.

[0071] Here, an individual coil (110, Individual Coil) refers to an individual coil unit that is independently wound and manufactured corresponding to each slot or pole, rather than the entire winding of the motor being made up of a single continuous wire. By dividing the coil into individual units in this way, the fill factor of the coil can be maximized regardless of the shape of the stator core, and there is an advantage in increasing the mass production of the coil itself.

[0072] FIG. 1 is a schematic diagram illustrating, exemplarily, the winding shape of individual coils according to one embodiment of the present invention. In one embodiment, individual coils (110) may be formed by winding a flat wire. The flat wire may include a conductor having a cross-section that is approximately rectangular or flat, which may be advantageous for increasing the conductor filling rate relative to the occupied space, increasing the heat transfer area, or stabilizing the winding shape. However, the present invention is not limited to using individual coils (110) formed by winding a flat wire, and plate-shaped or linear conductive conductors or wires may be used.

[0073] Individual coils (111, 112) may be formed to have spiral or helical windings. Here, a spiral may be exemplified as a spiral shape extending within a plane, and a helical shape may be exemplified as a coil shape proceeding in the axial direction, but for the purposes of the invention, any winding shape that can be repeatedly produced by a winding machine / process is sufficient, and the winding shape may be varied according to design purposes (e.g., occupied area, terminal location, inductance / resistance, cooling structure).

[0074] Additionally, multiple individual coils (110) can be wound in the same rotational direction. This can contribute to standardizing individual coils to simplify manufacturing and inventory / quality control, and to allow individual coils to be treated like module components. Here, the same rotational direction may mean that the turns are standardized to be formed in the same direction (e.g., clockwise or counterclockwise) from the perspective of the winding process. Furthermore, even if the winding direction of the individual coils is the same, the direction of current application (polarity) between coils can be controlled through the design of the conductive pattern (130) of the printed circuit board (140), so that it can respond to the motor's magnetic field formation requirements (e.g., alternating magnetic field direction formation between adjacent coils).

[0075] In a specific embodiment, a plurality of individual coils (110) may be standardized by being wound in the same rotational direction (winding direction). Generally, the direction (polarity) of the magnetic flux (or magnetic field) formed by the coil can be determined not only by the winding direction itself but also by the direction of current flow (current application direction) applied to both ends of the coil (e.g., magnetic field direction according to the right-hand rule). Therefore, even if the individual coils (110) are all wound in the same rotational direction, the polarity of the magnetic field formed by the individual coil (110) may be reversed depending on which terminal (110-1) of each individual coil (110) is powered (or which terminal is connected to a reference potential) and which terminal is current flowed out. The present disclosure is configured to take these points into consideration, so that in the manufacturing stage of individual coils (110), the winding direction of the coils is unified into a single direction to simplify the winding process (equipment, jig, inspection standard, inventory management, etc.), while in the assembly stage, the direction of current application between coils (polarity relationship) can be controlled in a desired way through the design of a conductive pattern (130) on a printed circuit board (140).

[0076] More specifically, in one embodiment, the conductive pattern (130) of the printed circuit board (140) may include an alternating connection wiring structure that connects a plurality of adjacent individual coils (110) by mutually reversing the direction of current application. For example, when the first terminal (111-1) and the second terminal (111-2) of the first individual coil (111) and the first terminal (112-1) and the second terminal (112-2) of the second individual coil (112) are bonded to corresponding bonding pads (120) of the printed circuit board (140), the conductive pattern (130) may have a cross-connection form in which (i) the first terminal (111-1) of the first individual coil (111) is electrically connected to the second terminal (112-2) of the second individual coil (112), and (ii) the second terminal (111-2) of the first individual coil (111) is electrically connected to the first terminal (112-1) of the second individual coil (112). Such terminal cross-connection provides the effect of mutually reversing the direction of current flowing in adjacent coils while using individual coils (110) manufactured in the same winding direction, thereby allowing adjacent coils within the stator module (100) to form alternating polarities (e.g., magnetic field distribution corresponding to an alternating magnetic pole arrangement). Furthermore, this alternating connection is not limited to merely reversing polarity, but can also function as a means to match the electrical connection polarity of each individual coil (110) when configuring a phase winding by connecting multiple individual coils (110) in series or parallel, so that the desired winding effect is added (e.g., to form a series addition relationship).

[0077] In addition, the alternating connection wiring structure is not limited to the cross connection example described above, and various modifications are possible to achieve an equivalent effect, such as configuring the direction of current application between adjacent coils to alternate through the arrangement direction of individual coils (110) (whether rotation / inversion arrangement is possible), terminal definition (first / second terminal), arrangement of bonding pads (120), layer configuration of the conductive pattern (130) (upper / lower / internal layer of the multilayer printed circuit board (140)), vias, or equivalent interlayer connection means. Consequently, according to the present invention, in the coil manufacturing stage, individual coils (110) are standardized in a single direction to improve productivity, and in the assembly stage, polarity relationships between coils and magnetic field distribution can be flexibly implemented simply by changing the design of the conductive pattern (130) of the printed circuit board (140), thereby improving responsiveness to motor specifications (e.g., phase winding configuration, connection topology, magnetic field arrangement requirements).

[0078] In one embodiment, a plurality of individual coils (110) each have two ends, i.e., terminals (110-1), for power application or electrical connection. As a more specific example, the terminal (110-1) may refer to an area where the conductor of the individual coil (110) is exposed or a connection structure is provided so as to be electrically connected to the outside. For example, the first individual coil (111) may include a first terminal (111-1) and a second terminal (111-2), and the second individual coil (112) may include a first terminal (112-1) and a second terminal (112-2). The terminal may be an exposed part of the conductor itself, or it may be in the form of a tab, lug, conductive pad, or plate attached to the conductor, but is not limited thereto.

[0079] In one embodiment, the printed circuit board (140) may be a single-layer board, but in one embodiment, it may be implemented as a multilayer printed circuit board including a plurality of layers. The multilayer structure can be advantageous for improving the degrees of freedom and wiring density of coil connections, and for separating and arranging power patterns for forming phase windings and sensor / signal patterns (e.g., encoder signal lines) by layer.

[0080] In one embodiment, the conductive pattern (130) included in the printed circuit board may include a pattern for forming a phase winding and additionally include a pattern including an encoder signal line. For example, the pattern for forming the phase winding may be composed of a power pattern that transmits a relatively large current, and the encoder signal line may be composed of a signal pattern that requires relatively low current / low noise characteristics. These patterns may coexist on the same layer or may be separated into different layers to ensure electromagnetic interference and insulation distance.

[0081] Additionally, the conduction pattern (130) may include an end-winding connection that electrically connects the terminals (110-1) of individual coils (110). Here, the term "end-winding connection" is not limited to the traditional sense of end-winding (a section where the end of a coil is bent and connected in an external space), but is used to encompass a connection section in the present invention where electrical connection between coil terminals is performed. That is, the end-winding connection may include a wiring pattern, a bridge pattern, a via connection structure between layers, a side conduction section, or a connection structure associated with a common connection area on the printed circuit board (140).

[0082] The conduction pattern (130) and the end-winding connection may be formed to implement at least one of a series connection, a parallel connection, a star connection, or a delta connection between a plurality of individual coils (110). For example, it is possible to have a design that increases voltage by connecting individual coils constituting a specific phase winding in series, a design that increases current capacity by connecting them in parallel, or a design that selectively implements a star / delta connection in a three-phase motor. Since this connection topology can be changed by modifying the design of the conduction pattern (130) of the printed circuit board (140) without changing the individual coils themselves, it is advantageous in terms of platformization / modularization.

[0083] In the present disclosure, the common connection area may be provided as an area for connecting some of the terminals of a plurality of individual coils in common. The common connection area may function as a star point in a star connection or as a common bus node in a specific parallel connection. Additionally, the common connection area may be implemented in the form of a pad with an expanded area to increase the reliability of the soldering process, or may be implemented to include a metal area expansion portion for heat dissipation.

[0084] In one embodiment, the printed circuit board (140) may include a positioning structure for arranging a plurality of individual coils (110). The positioning structure may include, for example, a guide groove or a mounting alignment mark. Although not shown in the drawing, a guide groove that guides the individual coils (110) to be mounted in a correct position, or an alignment mark for recognition by a vision system, may be formed on the surface of the printed circuit board (140). Here, a guide groove may refer to a shape in which a part of the outer shape of the individual coil (110) is seated or fitted to define the position and / or rotation angle of the individual coil (110). For example, the guide groove may be a groove formed in the main body of the printed circuit board (140), or a groove in an insulating structure (e.g., a resin molding part) additionally formed on the board, and is not limited to a specific forming method. Additionally, the mounting alignment mark may refer to a reference mark provided on a substrate so that it can be recognized by an automatic placement device (e.g., a vision alignment device). The alignment mark can be implemented in various ways, such as silk printing, laser marking, or metal pattern formation, and the shape of the mark can also be varied in various ways, such as circular, square, or cross shape. In the present disclosure, the positioning structure is not limited to a guide groove or an alignment mark, and may include various modified structures, such as a reference hole, stopper, recess, projection, or pin-hole alignment structure.

[0085] In one embodiment, the terminals (110-1) of individual coils may be configured to be bonded to bonding pads (120) in a surface mount manner. In the present disclosure, the surface mount method may comprehensively refer to a method in which the terminals (110-1) are arranged to be directly bonded to the surface-side bonding pads (120) of the substrate (140), and bonding is performed without relying on manual lead wire connections. Accordingly, the surface mount method is not limited to the same process as a conventional electronic component SMT process, but may include a mounting / bonding method modified to suit the terminal structure of the motor winding. The surface mount method is advantageous for treating individual coils as module components and placing / bonding them on a substrate using automated equipment, and the terminal shape (e.g., tab, flat terminal) and pad shape (e.g., land pattern) can be designed to suit this.

[0086] For example, in the present invention, the individual coil (110) itself, composed of the aforementioned balanced conductor, can be treated as a single independent SMD (Surface Mount Device) inductor component. In one embodiment, individual coils (110) mass-produced in the same direction through a general-purpose spring winder, etc., can be loaded onto a reel or tray, which is an electronic component supply device, and supplied to a standard high-speed pick-and-place equipment. That is, the individual coil (110) has a geometric shape and terminal structure as a standardized electronic component that can be adsorbed and precisely transported by a robot arm, just like a chip resistor or chip inductor.

[0087] Next, the high-speed pick-and-place equipment can arrange a plurality of individual coils (110) at ultra-high speed with ultra-small (e.g., in micron (μm) units) precision on the bonding pad (120) of the printed circuit board (140) on which solder paste is pre-printed. Finally, by passing the printed circuit board (140) on which the coils are arranged through a standard reflow soldering machine, the terminals (110-1) of all individual coils (110) on the board and the bonding pad (120) are soldered together in batches.

[0088] Consequently, the present invention provides a groundbreaking technical foundation that enables the elimination of manual elements in the motor manufacturing process and the achievement of full process automation by converting motor coils into standardized SMD components that can be mass-produced without a dedicated winding machine and assembling them in batches using a general-purpose SMT line.

[0089] At this time, the joining of the terminals and the bonding pads can be performed by at least one method of soldering or welding. Soldering can be performed by various processes such as reflow, hot bar, and high-frequency (induction heating) soldering, and welding can be implemented by laser welding, resistance welding, ultrasonic welding, etc. Since the present invention focuses on a structural concept of realizing substrate pattern connections through substrate pad-coil terminal joining, the joining method can be appropriately selected according to design / material / current capacity / thermal reliability requirements.

[0090]

[0091] FIG. 3 is a schematic diagram showing a connection or wiring structure inside a printed circuit board according to one embodiment of the present disclosure.

[0092] In one embodiment of the present disclosure, the printed circuit board (140) may be a multilayer printed circuit board comprising a plurality of layers. The multilayer structure may be advantageous for (i) separating power transmission patterns and signal transmission patterns by layer, (ii) implementing complex connections (series / parallel / star / delta) within a limited board area, or (iii) reducing electrical interference and securing insulation distance. In the multilayer printed circuit board (140), electrical connections between layers may be provided by vias, through-conductors, or equivalent layer connection means.

[0093] In one embodiment, the conductive pattern (130) of the printed circuit board (140) may include an alternating connection wiring structure that connects the current application directions between a plurality of adjacent individual coils (110) by reversing them.

[0094] For example, when a first individual coil (111) and a second individual coil (112) are arranged adjacently, the conductive pattern (130) may have a cross-connection form in which the first terminal (111-1) of the first individual coil (111) is electrically connected to the second terminal (112-2) of the second individual coil (112), and the second terminal (111-2) of the first individual coil (111) is electrically connected to the first terminal (112-1) of the second individual coil (112). Such a connection relationship can provide the effect of reversing the direction of the current applied to adjacent coils even if the winding direction of the individual coils is the same. For example, the alternating connection wiring structure can be implemented by utilizing three-dimensional wiring (e.g., inter-layer crossing) of a multilayer PCB.

[0095] The alternating connection wiring structure is not necessarily limited to the cross connection type described above, and various pattern variations are possible to achieve an equivalent electrical effect (alternating direction of adjacent coil currents) depending on terminal definitions (first / second terminals), pad placement, layer configuration, etc.

[0096]

[0097] FIG. 4 is another diagram schematically showing a housing and heat dissipation channel structure integrated with a printed circuit board according to one embodiment of the present disclosure.

[0098] In one embodiment of the present invention, a metal frame or reinforcing plate may be integrally attached to the outer periphery of the printed circuit board (140). Accordingly, the printed circuit board (140) may be configured to function as at least part of the housing of the stator module (100). For example, the metal frame / reinforcing plate may perform roles such as improving mechanical rigidity, providing fastening parts, protecting against external forces, and providing a heat dissipation path. Such integral attachment may be implemented in various ways, such as fastening, riveting, bonding, insert molding, and overmolding, and is not limited to a specific method. In this regard, the metal frame or reinforcing plate may perform roles such as, for example, securing rigidity of the board (140), providing a mounting part for the stator module (100), reinforcing the structure in an external force / vibration environment, or providing a heat diffusion path. However, the shape and method of attachment of the frame / reinforcing plate may be varied depending on the application field and design conditions of the motor. By having the printed circuit board serve as the external housing for the stator module, the number of parts and assembly process can be drastically reduced.

[0099] Additionally, the printed circuit board (140) may include a heat dissipation passage or heat dissipation channel for discharging heat generated from a plurality of individual coils (110) to the outside. The heat dissipation passage / channel can be broadly interpreted as a concept including a metal surface (copper surface) extension for heat diffusion, a thermal via array, a heat transfer path to a metal core, a thermally conductive filling layer, or a thermal contact surface structure with a housing / frame. Additionally, the channel may be interpreted as a channel for fluid cooling, but the present disclosure does not necessarily require fluid cooling and can be broadly interpreted to include a conduction / diffusion-based heat transfer path. Referring to FIG. 4, a schematic structure of the housing and the heat dissipation channel is illustrated.

[0100] In one embodiment, the printed circuit board (140) may be formed as a metal core printed circuit board (Metal Core PCB) or may include a thermally conductive resin. For example, the MCPCB is advantageous for rapidly diffusing / releasing heat through the metal core, and the thermally conductive resin may include a resin material for improving the thermal conductivity of the insulating layer or the filling layer. Such a thermally conductive resin can contribute to mitigating heat generation in the coil terminal junction and power pattern by improving the thermal conductivity of the insulating layer or the filling layer.

[0101]

[0102] FIG. 5 is a schematic diagram showing a state in which a sensor is embedded in a printed circuit board according to one embodiment of the present disclosure.

[0103] In one embodiment, the printed circuit board (140) may include a temperature sensor for monitoring the temperature of at least some of the plurality of individual coils (110). The temperature sensor may be placed within a layer of the printed circuit board (140) or mounted on the printed circuit board (140). For example, the temperature sensor may be placed near the coil terminal junction, near the power pattern, or in an area where heat concentration is expected to increase monitoring sensitivity.

[0104] Additionally, the conduction pattern (130) may include a pattern including an encoder signal line along with a pattern for forming a phase winding. The encoder signal line may be used as wiring to transmit signals from a sensor (e.g., Hall sensor, magnetic / optical encoder) for acquiring rotational position / speed information of the rotor (200), and designs such as layer separation, grounding patterns, and shielding patterns may be applied to reduce interference with the power pattern. In this disclosure, the encoder signal line may refer to a signal transmission line associated with an encoder or rotation sensor that detects information such as the position / speed of the rotor (200). The encoder signal line may be formed on the same layer as the power pattern through which the phase winding current flows, but in one embodiment, it may be separated and placed on a different layer to reduce electromagnetic interference, or placed in combination with a grounding pattern or a shielding pattern. However, the specific wiring method of the signal line is not limited to a specific method. As such, the present invention allows the sensor to be embedded in a printed circuit board, thereby eliminating separate sensor wiring and end-winding sections, which can reduce the overall volume and weight of the motor.

[0105] Additionally, the printed circuit board (140) may further include at least one of a pressure sensor or a vibration sensor for motor condition diagnosis. For example, the vibration sensor may be applied to detect bearing abnormalities, imbalances, resonance, etc., and the pressure sensor may be applied to monitor the condition of a cooling structure or a sealed space. This sensor integration can be utilized to reduce wiring complexity of the stator module (100) and to improve modularity and assembly.

[0106]

[0107] According to one embodiment of the present invention, the motor may include a stator module (100) and one or more rotors (200) axially opposed to the stator module (100). The rotors (200) may be configured to form electromagnetic interactions with an axial air gap by being axially opposed to the stator module (100). The specific configuration of the rotors (200) (e.g., permanent magnet type, reluctance type, etc.) may vary depending on the purpose of application and design specifications. Since the core of the present invention lies in the individual coil-PCB connection integrated structure of the stator module (100), the scope of rights is not unnecessarily limited by the configuration of the rotors (200). For example, the rotors (200) may include permanent magnets, reluctance structures, or other rotor structures, and the number of rotors may also take various forms, such as a single rotor or dual rotors. Furthermore, the term "one or more rotors" naturally implies including a single rotor.

[0108] Additionally, a method for manufacturing a motor may include the steps of winding a flat wire to form a plurality of individual coils (110), preparing a printed circuit board (140) including a plurality of junction pads (120) and a conductive pattern (130), placing individual coil terminals (110-1) on the junction pads (120) and joining them to form a stator module (100), and joining a rotor (200) so as to be axially opposed to the stator module (100). At this time, the connection structure of the phase winding (e.g., series / parallel / star / delta, common connection area, alternating connection wiring structure) can be implemented through the design of the conductive pattern (130) of the printed circuit board (140).

[0109] In the method for manufacturing a motor of the present disclosure, the step of winding a flat wire to form individual coils (110) can be interpreted as a process for standardizing and repetitive production of individual coils (110). After winding, subsequent processes such as bending, exposing (removing insulation), or reinforcing the terminal portion (attaching a tab / plate) may be performed to form a terminal (110-1), but such subsequent processes are exemplary processes selected as necessary and are not necessarily limited.

[0110] Additionally, the step of preparing a printed circuit board (140) can be understood as the step of providing a board comprising bonding pads (120) and a conductive pattern (130). The conductive pattern (130) may include, depending on the design purpose, a pattern for forming a phase winding, an end-winding connection, a serial / parallel / star / delta implementation pattern, an alternating connection wiring structure, a common connection area, or an encoder signal line.

[0111] Next, in the step of forming a stator module (100) by placing the terminal (110-1) on the bonding pad (120) and bonding it, a positioning structure (guide groove / alignment mark) may be utilized for placement precision and automation. Bonding may be performed by soldering or welding, and may be implemented, for example, by a surface mount method. After bonding, conventional quality verification processes such as electrical continuity inspection, insulation inspection, and appearance inspection may be performed, but these are exemplary processes selected according to production conditions.

[0112] Finally, in the step of joining the rotor (200), the rotor (200) may be joined so as to be axially opposed to the stator module (100), and the motor housing and bearing structure, etc., may be configured in various ways depending on the application design. The manufacturing method of the present invention is not limited to the specific method of joining the rotor (200) or the housing structure, and the essence lies in the formation of the stator module (100) and its structural features.

[0113]

[0114] Description of the presented embodiments is provided to enable those skilled in the art to use or practice the present disclosure. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments without departing from the scope of the present disclosure. Thus, the present disclosure is not limited to the embodiments presented herein, but should be interpreted in the broadest possible scope consistent with the principles and novel features presented herein.

[0115] As described above, the relevant details have been described in the best mode for carrying out the invention.

Claims

1. As a stator module for a motor, Multiple individual coils; and A printed circuit board comprising a plurality of bonding pads formed so that the terminals of each of the plurality of individual coils can be bonded, and a conductive pattern that electrically connects the plurality of bonding pads. Includes, The terminals of the plurality of individual coils are joined to the plurality of joining pads, The above-described conduction pattern is configured to electrically connect the plurality of individual coils to form at least one phase winding, Stator Module.

2. In Paragraph 1, Each of the above plurality of individual coils is formed by winding a flat wire, Stator Module.

3. In Paragraph 2, The above plurality of individual coils are wound in the same rotational direction, Stator Module.

4. In Paragraph 3, The conductive pattern of the above printed circuit board is, A plurality of adjacent individual coils having an alternating connection wiring structure that connects them by mutually reversing the direction of current application between them, Stator Module.

5. In Paragraph 2 or 3, The above plurality of individual coils are formed to have spiral or helical windings, Stator Module.

6. In Paragraph 1, The above printed circuit board includes a positioning structure comprising a guide groove or a mounting alignment mark for arranging the plurality of individual coils. Stator Module.

7. In Paragraph 1, The terminals of the plurality of individual coils are configured to be bonded to the plurality of bonding pads in a surface-mount manner. Stator Module.

8. In Paragraph 7, The joining of the above terminals and the plurality of joining pads is performed by at least one method of soldering or welding. Stator Module.

9. In Paragraph 1, The above printed circuit board is a multilayer printed circuit board comprising a plurality of layers, and The above challenge pattern is, It includes an end-winding connection portion that electrically connects the terminals of the plurality of individual coils, and Formed to implement at least one of a series connection, a parallel connection, a star connection, and a delta connection among the plurality of individual coils, Stator Module.

10. In Paragraph 9, The above printed circuit board further includes a common connection area for commonly connecting some of the terminals of the plurality of individual coils. Stator Module.

11. In Paragraph 1, The above printed circuit board is, A metal frame or reinforcing plate is integrally combined to the outer periphery, configured so that the printed circuit board functions as at least part of the housing of the stator module. Stator Module.

12. In Paragraph 1, The above printed circuit board includes a temperature sensor for monitoring the temperature of at least some of the plurality of individual coils, and The above temperature sensor is disposed within a layer of the printed circuit board or mounted on the printed circuit board, Stator Module.

13. In Paragraph 1 or Paragraph 12, The above challenge pattern includes a pattern for forming a phase winding and a pattern including an encoder signal line, Stator Module.

14. In Paragraph 12, The above printed circuit board further includes at least one of a pressure sensor or a vibration sensor for motor condition diagnosis. Stator Module.

15. In Paragraph 1, The above printed circuit board includes a heat dissipation passage or heat dissipation channel for discharging heat generated from the plurality of individual coils to the outside, and The above printed circuit board is formed as a metal core printed circuit board (Metal Core PCB) or comprises a thermally conductive resin, Stator Module.

16. In Paragraph 1, The above stator module is a coreless structure that does not include an iron core, Stator Module.

17. As a motor, Stator module; and One or more rotors axially opposed to the stator module above Includes, The above stator module is, Multiple individual coils; and A printed circuit board comprising a plurality of bonding pads formed so that the terminals of each of the plurality of individual coils can be bonded, and a conductive pattern that electrically connects the plurality of bonding pads. Includes, The terminals of the plurality of individual coils are joined to the plurality of joining pads, The above-described conduction pattern is configured to electrically connect the plurality of individual coils to form at least one phase winding, motor.

18. As a method for manufacturing a motor, A step of forming multiple individual coils by winding a conductive wire; A step of preparing a printed circuit board comprising a plurality of bonding pads and a conductive pattern that electrically connects the plurality of bonding pads; A step of arranging the terminals of the plurality of individual coils on the plurality of bonding pads and bonding the terminals and the bonding pads to form a stator module; and A step of combining one or more rotors so as to be axially opposed to the stator module above. Includes, The above-described conduction pattern is configured to electrically connect the plurality of individual coils to form at least one phase winding, method.

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