Coreless Motor Coil Structure with Polygonal Spiral Traces
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Solution Overview
Problem
Conventional coil structures for coreless motors have non-effective areas due to inefficient winding arrangements, leading to reduced electromagnetic effect and performance.
Innovation Solution
A coil structure with first and second conductive traces arranged in planar spiral configurations of polygonal, triangular, or rhombic shapes, where the second traces fill the spaces between adjacent first traces, increasing space utilization and reducing non-effective areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional winding arrangements (rectangular or hexagonal spiral) are used, then the coil structure is easier to manufacture, but non-effective areas are created between windings and end portions, reducing electromagnetic effect
Solution Approach 1:
The coil structure is divided into multiple effective windings arranged in a circular pattern, with each winding contributing to the electromagnetic effect. The circular arrangement segments the coil into identical units that can be manufactured separately and then assembled, eliminating the non-effective areas present in conventional rectangular or hexagonal configurations.
Solution Approach 2:
The patent transitions from planar rectangular or hexagonal spiral windings to a three-dimensional circular winding arrangement. This dimensional change allows the windings to be stacked and interconnected through the substrate, creating a more efficient use of space and eliminating dead areas between windings.
2Reliability
If both sides of the substrate are provided with windings, then the electromagnetic effect is enhanced, but large areas must be spared in the middle for conductive vias, creating wasted non-effective areas
Solution Approach 1:
The patent implements a nested structure where windings on one side of the substrate are interconnected with corresponding windings on the other side through conductive vias. The inner windings are positioned within the circular pattern, allowing efficient use of the substrate area while maintaining electromagnetic effectiveness.
Solution Approach 2:
The patent utilizes the third dimension (through-substrate vias) to interconnect windings on opposite sides, allowing the windings to be positioned closer together and reducing the need for large central areas. This vertical interconnection method eliminates the wasted space required in planar configurations.
3Device complexity
If rectangular spiral configuration is used, then the winding arrangement is simpler, but more extraneous end-windings are created, resulting in lower contribution to operation for the same copper loss
Solution Approach 1:
The circular winding configuration is segmented into multiple identical effective windings, each contributing equally to the electromagnetic effect. This segmentation eliminates the extraneous end-windings present in rectangular configurations, ensuring that all copper material contributes to the operational performance.
Solution Approach 2:
The patent changes the geometric parameters of the winding configuration from rectangular to circular, which fundamentally alters the distribution of current paths. This parameter change eliminates dead areas and ensures that the entire copper winding contributes to the electromagnetic effect, improving productivity per unit of copper loss.
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
This design enhances electromagnetic performance by optimizing space utilization and minimizing non-effective areas, leading to improved output power and efficiency in coreless motors.
Implementation Method 1
a coil structure for a coreless motor that includes a plurality of first conductive traces and a plurality of second conductive traces... increases space utilization, and that reduces non-effective areas of windings thereof, to thereby increase the electromagnetic effect of the coil structure
Data Source
AI summary
A coil structure for a coreless motor includes a plurality of first conductive traces and a plurality of second conductive traces. The first conductive traces are disposed in succession relative to one another, and are each arranged into a planar spiral configuration having a substantially polygonal shape. At least one adjacent pair of the first conductive traces cooperate to define a space therebetween. Each of the second conductive traces is disposed in the space defined by a corresponding adjacent pair of the first conductive traces, and is arranged into a planar spiral configuration that has one of a substantially triangular shape and a substantially rhombic shape so as to substantially fill the space.