Flexible Coil Substrate Winding Alignment Using Side Recesses
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Solution Overview
Problem
Existing coil substrates face challenges in aligning wirings properly when wound into a cylindrical shape, leading to potential winding misalignment and ineffective torque generation in motor coils, particularly with flexible substrates where marks for positioning are difficult to confirm during multiple turns.
Innovation Solution
A coil substrate with a flexible substrate featuring recesses on its sides, allowing for precise alignment of inner and outer circumferential wirings by overlapping recesses when wound, ensuring proper alignment and reducing torque ripple.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If marks are used for positioning during winding of flexible substrate, then alignment of wirings can be achieved, but marks become difficult to confirm during multiple turns
Solution Approach 1:
The patent extracts the positioning function from traditional surface marks and relocates it to recesses formed on the side surface of the flexible substrate. These recesses are created by removing material to a predetermined depth, creating physical features that can be detected by sensors during the winding process. This extraction solves the problem of mark detectability while maintaining alignment precision.
Solution Approach 2:
The patent replaces the optical detection method (visual confirmation of marks) with a mechanical sensing method. Sensors detect the physical presence and position of recesses on the substrate side surface during winding, enabling precise alignment control without relying on visual mark confirmation. This substitution resolves the contradiction between maintaining precision and improving detectability.
2Ease of manufacture
If traditional winding alignment methods are used, then manufacturing process is simple, but winding misalignment occurs leading to ineffective torque generation
Solution Approach 1:
The patent implements preliminary action by pre-forming recesses on the flexible substrate before the winding process. These recesses serve as predetermined positioning features that guide the winding alignment. During winding, the substrate is positioned based on these pre-formed recesses, ensuring accurate alignment of inner and outer circumferential wirings. This preliminary preparation maintains manufacturing simplicity while significantly improving torque generation reliability by preventing misalignment.
3Manufacturing precision
If recesses are formed on flexible substrate sides, then wiring alignment precision is improved, but substrate structure becomes more complex
Solution Approach 1:
The patent applies segmentation by dividing the substrate structure into distinct functional regions: the main flexible substrate body and the recesses formed on its side surface. The recesses are segmented features with specific depths and positions that serve the positioning function without complicating the overall substrate structure. This segmentation allows precise wiring alignment while maintaining a relatively simple and manufacturable substrate design.
Data Source
AI summary
A coil substrate includes a flexible substrate having a first surface and a second surface on the opposite side with respect to the first surface, and coils including first wirings and second wirings such that the first wirings are formed on the first surface of the flexible substrate and that the second wirings are formed on the second surface of the flexible substrate. The flexible substrate has one or more recesses formed on one or more longitudinal sides of the flexible substrate and is formed to be wound in a circumferential direction around an axis extending in the width direction of the flexible substrate orthogonal to the longitudinal direction of the flexible substrate such that the flexible substrate is formed into a cylindrical shape.