Axial Gap Motor Stator PCB Layout for Coil Position Stability
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Solution Overview
Problem
The positional deviation of coils with respect to the substrate in axial gap motors due to impacts affects the output characteristics, necessitating improved impact resistance and positional stability.
Innovation Solution
A stator design incorporating a multilayer printed circuit board with alternating coil patterns on insulating layers, enhancing impact resistance and positional stability through distributed winding and integrated sensor installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If coils are disposed on a substrate in an axial gap motor, then the motor structure is simplified and manufacturing is easier, but the coil position may shift when impact is applied, affecting output characteristics
Solution Approach 1:
The patent transitions from a single-layer coil arrangement to a multi-layer PCB structure, utilizing the vertical dimension (thickness direction) to distribute coil patterns across multiple insulating layers. This dimensional change allows coils to be firmly embedded within the substrate structure, preventing positional shifts while maintaining manufacturing simplicity through standardized multi-layer PCB fabrication processes.
Solution Approach 2:
The patent employs a composite structure combining multiple insulating layers with conductor patterns embedded within them, forming an integrated multi-layer PCB. This composite material approach provides both mechanical support and electrical functionality, ensuring coil patterns remain fixed while maintaining ease of manufacture through established PCB manufacturing techniques.
2Reliability
If multiple insulating layers with coil patterns are used, then impact resistance and positional stability are improved, but the stator thickness increases
Solution Approach 1:
The patent utilizes thin insulating layers and conductor patterns that are integrated within each layer, optimizing the thickness of individual components. By employing thin-film technology and efficient layer stacking, the design achieves high impact resistance and positional stability while minimizing the overall stator thickness through compact, multi-layer construction.
3Manufacturing precision
If coil patterns are formed in multiple insulating layers, then positional deviation is prevented and output characteristics are maintained, but the manufacturing process becomes more complex
Solution Approach 1:
The patent leverages the universal applicability of standardized multi-layer PCB manufacturing processes, which are already widely used in the electronics industry. By adopting this proven technology, the patent achieves high positional accuracy for coil patterns while avoiding the need to develop complex custom manufacturing processes, thus maintaining manufacturing simplicity despite the multi-layer structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design ensures coil patterns remain fixed on the substrate, improving impact resistance, reducing thickness, and maintaining accurate rotation control while simplifying manufacturing processes.
Implementation Method 1
first coil patterns formed of conductor patterns in the first insulating layer; and second coil patterns formed of conductor patterns in the second insulating layer
Data Source
AI summary
A stator, of an axial gap motor, includes a printed circuit board having insulating layers including first and second insulating layers, first coil patterns formed of conductor patterns in the first insulating layer, and second coil patterns formed of conductor patterns in the second insulating layer.