Cylindrical Motor Coil Substrate for Torque and Yoke Adhesion
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Solution Overview
Problem
Existing motor coil substrates face challenges in achieving high torque and stability due to inadequate adhesion strength with the yoke and inefficient use of space in small motors.
Innovation Solution
A motor coil substrate design featuring a flexible substrate with coils wound in a cylindrical shape, where the first surface is on the inner circumferential side and the second surface is on the outer circumferential side, ensuring a cylindricity of 0.0 mm to 0.3 mm, with a space factor of 50% to 99% and wiring ratio of 80.0% to 99.9%, enhancing adhesion and torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the flexible substrate is wound into a cylindrical shape with high cylindricity (0.0-0.3 mm), then the adhesion strength with the yoke and torque are improved, but the manufacturing precision requirements become more stringent
Solution Approach 1:
The patent specifies a precise cylindricity parameter range (0.0-0.3 mm) for the wound flexible substrate. By controlling this geometric parameter within the defined range, the substrate achieves optimal adhesion strength to the yoke while maintaining manufacturability. This parameter optimization resolves the contradiction by identifying the specific cylindricity threshold that balances manufacturing feasibility with performance requirements.
2Power
If the space factor is increased to 50-99% and wiring ratio to 80.0-99.9%, then torque and space utilization are improved, but the device complexity increases
Solution Approach 1:
The patent utilizes both surfaces of the flexible substrate (first surface and second surface) for winding coils, effectively using two-dimensional space on opposite sides of the substrate. This dimensional approach allows high space factor (50-99%) and wiring ratio (80.0-99.9%) without proportionally increasing complexity, as the coils are organized in systematic layers on each surface rather than random three-dimensional arrangements.
Solution Approach 2:
The patent applies different coil configurations to different regions of the flexible substrate, with U-phase, V-phase, and W-phase coils arranged in specific patterns on the first and second surfaces. This local optimization allows high torque output while maintaining manageable complexity through systematic regional organization of the wiring structure.
3Volume of moving object
If coils are formed on both sides of the flexible substrate, then space utilization and torque are improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent divides the coil formation process into separate stages for the first surface and second surface of the flexible substrate. By segmenting the manufacturing process into distinct phases (forming coils on first surface, then forming coils on second surface), the complexity is managed through systematic breakdown of operations, enabling high space utilization without overwhelming manufacturing complexity.
Data Source
AI summary
A motor coil substrate includes a flexible substrate, and coils including wirings such that the wirings are formed on a first surface of the flexible substrate and a second surface on the opposite side with respect to the first surface. The flexible substrate is wound circumferentially from one end of a longitudinal direction of a flexible substrate around an axis extending in a direction perpendicular to the longitudinal direction of the flexible substrate such that the flexible substrate is formed into a cylindrical shape and that a cylindricity of an outer circumferential surface is greater than 0.0 mm and equal to or less than 0.3 mm.