Cylindrical Flexible Board Laminate for Continuous Stator Windings
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Solution Overview
Problem
Conventional rotating electrical machines with stator coils formed from flexible circuit boards face challenges in weight reduction and energy efficiency due to complex manufacturing processes and potential electrical discontinuities at connection points, leading to heat generation and reduced magnetic susceptibility.
Innovation Solution
A board laminate comprising strip-shaped flexible circuit boards bent into a cylindrical shape, with continuous wires formed on both surfaces and connected via vias, creating a chain-like configuration that reduces weight and improves energy efficiency by simplifying the manufacturing process and minimizing heat generation through efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional flexible circuit board stator coils are used, then weight reduction is achieved, but manufacturing complexity increases and electrical discontinuities occur at connection points
Solution Approach 1:
The patent merges multiple separate wire segments into a single continuous wire that passes through multiple slots and coils without interruption. This eliminates the need for separate connection points and joining operations, thereby reducing manufacturing complexity while maintaining the weight benefits of flexible circuit board construction.
Solution Approach 2:
The continuous wire is pre-formed with the complete path through all slots and coils before assembly. This preliminary configuration of the wire path eliminates the need for complex on-site connection operations, reducing manufacturing complexity while preserving weight reduction advantages.
2Weight of moving object
If conventional flexible circuit board stator coils are used, then weight reduction is achieved, but electrical resistance increases due to connection discontinuities
Solution Approach 1:
The patent combines multiple wire segments into one continuous wire structure that spans multiple coils and slots without interruption. This merging eliminates connection discontinuities and associated electrical resistance, improving reliability while maintaining the weight benefits of flexible circuit board construction.
3Ease of manufacture
If conventional connection methods are used, then manufacturing is simplified, but heat generation increases at connection points
Solution Approach 1:
The patent extracts and eliminates the connection points that generate heat from the coil structure. By using a continuous wire that passes through slots without requiring joins or connections between segments, the harmful heat generation at connection points is removed while maintaining manufacturing simplicity.
Solution Approach 2:
The patent converts the potential harm of wire routing complexity into a benefit by designing a continuous wire path that naturally routes through slots without requiring connections. This approach eliminates heat-generating connection points while the slot routing provides organized, manageable wire placement that simplifies manufacturing.
4Use of energy by moving object
If continuous wires with chain-like configuration are used, then energy efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent uses the natural curvature and flexibility of the continuous wire to adapt to the cylindrical rotor geometry. The wire is routed through slots in a curved path that follows the rotor's circular shape, eliminating the need for high precision straight-line positioning while maintaining optimal energy efficiency through continuous current flow.
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 enables a rotating electrical machine with reduced weight and improved energy efficiency by simplifying the manufacturing process, reducing electrical resistance, and maintaining high magnetic susceptibility through efficient heat dissipation.
Implementation Method 1
the partial wires formed on each main surface being alternately connected in cascade via vias
Data Source
AI summary
A board laminate includes a plurality of strip-shaped flexible circuit boards bent into a cylindrical shape and stacked in a radial direction of the cylinder. Each of a plurality of the flexible circuit boards includes a continuous wire formed by a plurality of partial wires formed on each of two main surfaces of a strip-shaped insulating sheet and formed on each main surface are alternately connected in cascade via vias. The continuous wire has crossings in a chain-like shape without electrical continuity with each other in a projection plan view seen in a normal direction of the main surface of the insulating sheet, to form a plurality of annular portions. In a plurality of the flexible circuit boards, the flexible circuit board has a longer length of the insulating sheet as the flexible circuit board is placed further from a central axis of the cylinder.