3D Coil Layout for PCB-Integrated Disc Rotor Drives
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Solution Overview
Problem
Conventional PCB manufacturing methods for electric drives, such as surface-mounted or triangular concentric electric lines, fail to leverage the advantages of additive manufacturing, particularly in creating 3D coil structures for electric drives, leading to inefficiencies in integrating electric motors within PCBs.
Innovation Solution
An apparatus and method for generating a layout for additive manufacturing of electric drives using a parametric computer-aided design model, which includes an input module for user parameters and a generating module to create coil structures and control structures, adhering to constraints of additive manufacturing, such as material properties and resolution, to produce a feasible layout for electric drives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional PCB manufacturing methods (surface-mounted or triangular concentric electric lines) are used, then the manufacturing process is simple and well-established, but the integration of electric motors within PCBs is inefficient and 3D coil structures cannot be created
Solution Approach 1:
The patent merges the PCB substrate and coil structures into a single integrated component manufactured through additive manufacturing. The multi-material jetting printer deposits conductive and insulating materials simultaneously to create both the PCB base layer and 3D coil structures in one manufacturing process, eliminating the need for separate assembly steps and enabling direct integration of electric motor components within the PCB.
Solution Approach 2:
The patent transitions from conventional 2D PCB trace patterns to 3D coil structures by utilizing the vertical dimension through additive manufacturing. The multi-material jetting printer can deposit materials in multiple layers with precise control over height and position, enabling the creation of raised coil structures that extend above the PCB surface, thereby achieving true 3D integration of motor components.
2Productivity
If conventional PCB manufacturing methods are used, then the manufacturing process is well-established, but the time needed for CAD modeling is excessive and 3D features are not achievable
Solution Approach 1:
The patent replaces manual or conventional CAD modeling processes with automated algorithmic generation of toolpath data. The system automatically generates the 3D coil structure geometry and manufacturing paths based on input parameters, eliminating the need for extensive manual CAD modeling while simultaneously enabling complex 3D features that would be difficult or impossible to create using conventional 2D PCB design tools.
3Adaptability or versatility
If additive manufacturing with multi-material jetting printer is used, then 3D coil structures can be created and integration is improved, but constraints on material properties and resolution must be adhered to
Solution Approach 1:
The patent performs preliminary planning and optimization of the coil structure design before actual manufacturing. The system pre-calculates the toolpath data, material deposition patterns, and structural parameters to ensure that the design adheres to the multi-material jetting printer's constraints on material properties and resolution. This preliminary optimization ensures manufacturability while maintaining design flexibility.
4Volume of moving object
If conventional PCB methods with etching of copper stratum are used, then the manufacturing process is simple, but the electric drive integration is inefficient and cannot achieve compact motor integration
Solution Approach 1:
The patent implements nesting by integrating the coil structures directly within and on top of the PCB substrate in a nested configuration. The additive manufacturing process allows coil windings to be deposited within recesses of the PCB and to extend above the surface, creating a compact nested arrangement of motor components within the PCB volume, thereby achieving high compactness without requiring complex external assembly.
Data Source
AI summary
An apparatus for generating a layout for an additive manufacturing of an electric drive for a disc rotor. The disc rotor is adapted for being driven by a magnetic field. The apparatus comprises an input module configured to receive one or more input parameters. The apparatus further comprises a generating module configured to generate, from the one or more input parameters, a layout of a plurality of coil structures, wherein the plurality of coil structures is adapted to generate the magnetic field by an electric current, and a layout of a control structure, wherein the control structure is adapted to connect the plurality of coil structures with a connector for a supply of the electric current, and to distribute the electric current to the plurality of coil structures in order to drive the disc rotor.