Motor Coil Substrate with Variable Wiring Thickness
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Solution Overview
Problem
Existing coil substrates for motor coils face challenges in achieving a uniform thickness and reducing surface unevenness, leading to energy loss and potential eccentricity during rotation.
Innovation Solution
A coil substrate with a flexible substrate having coils formed in one row, featuring parallel and perpendicular wirings where the perpendicular wirings have a greater thickness than the parallel wirings, allowing for reduced resistance and efficient winding into a tubular shape with overlapping coils to minimize surface unevenness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional coil substrates are used with uniform wiring thickness, then manufacturing is simpler, but surface unevenness increases and energy loss occurs
Solution Approach 1:
The patent applies local quality by varying the wiring thickness according to its orientation: perpendicular wirings have a first thickness while parallel wirings have a second thickness (different from the first). This localized differentiation optimizes electrical properties and reduces energy loss in specific directions without requiring complete redesign of the entire wiring structure.
Solution Approach 2:
The patent changes the physical parameter of wiring thickness based on orientation. The perpendicular wirings have a different thickness parameter compared to parallel wirings, allowing optimization of electrical resistance and energy efficiency in different directions of the coil substrate.
2Loss of energy
If perpendicular wirings are made thicker to reduce resistance, then energy loss decreases, but manufacturing precision requirements increase
Solution Approach 1:
The patent implements local quality by assigning different thickness values to perpendicular and parallel wirings. The perpendicular wirings have a greater thickness to reduce resistance and energy loss, while parallel wirings have a smaller thickness. This localized differentiation allows optimization of electrical properties without requiring ultra-precise control across the entire wiring 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 solution results in a motor coil substrate with reduced resistance, improved roundness, and minimized energy loss, preventing eccentricity and ensuring smooth rotation.
Implementation Method 1
the coils are formed such that a thickness of the perpendicular wirings is greater than a thickness of the parallel wirings
Data Source
AI summary
A coil substrate includes a flexible substrate having a first end and a second end on the opposite side with respect to the first end, and coils formed on the flexible substrate in substantially one row between the first end and the second end of the flexible substrate such that each of the coils has a center space and wirings surrounding the center space. The wirings in each of the coils include parallel wirings formed substantially parallel to a row direction extending from the first end toward the second end and perpendicular wirings formed substantially perpendicular to the row direction, and the coils are formed such that a thickness of the perpendicular wirings is greater than a thickness of the parallel wirings.