Flexible Circuit Board Protrusions for Stator Alignment
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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 heat generation issues at connection points, leading to decreased magnetic susceptibility and performance.
Innovation Solution
A board laminate comprising strip-shaped flexible circuit boards bent into a cylindrical shape, with protrusions and heat transfer patterns made of higher thermal conductivity materials, allowing for efficient heat dissipation and improved alignment of coils, reducing weight and enhancing energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If flexible circuit boards are used to form stator coils, then weight of the rotating electrical machine is reduced, but manufacturing precision deteriorates due to alignment difficulties of connection points
Solution Approach 1:
A positioning protrusion is introduced as an intermediary element on the flexible circuit board that mediates the alignment between multiple boards during stacking. This protrusion fits into corresponding positioning grooves on adjacent boards, serving as a physical mediator that ensures precise alignment of connection points without requiring complex external fixtures or adjustment mechanisms.
Solution Approach 2:
The positioning protrusions and grooves are pre-formed on the flexible circuit boards during manufacturing, enabling automatic alignment to be built into the structure itself. This preliminary action eliminates the need for post-assembly alignment adjustments and ensures consistent positioning accuracy across all stacked boards.
2Device complexity
If flexible circuit boards are stacked and connected, then device complexity is reduced, but heat dissipation capability deteriorates at connection points
Solution Approach 1:
Thermal conduction plates are selectively placed at the connection points between stacked flexible circuit boards, where heat generation is most intense. These plates have higher thermal conductivity than the surrounding insulating materials, creating local zones of enhanced heat dissipation capability precisely where needed, without requiring the entire structure to be made of thermally conductive materials.
Solution Approach 2:
The connection structure employs a composite design combining insulating materials (for electrical isolation) with thermally conductive plates (for heat dissipation). This composite approach allows simultaneous achievement of electrical insulation and thermal management functions at the connection points between flexible circuit boards.
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 simplifies the manufacturing process, reduces weight, and improves energy efficiency by efficiently dissipating heat and aligning coils accurately, maintaining high magnetic susceptibility and operational performance.
Implementation Method 1
the protrusion of the flexible circuit board is provided with a heat transfer pattern made of a material with higher thermal conductivity than the insulating sheet
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 strip-shaped insulating sheet, a plurality of partial wires formed on each of two main surfaces of the insulating sheet, and protrusions placed on long sides extending in a longitudinal direction of the strip-shaped insulating sheet. When a plurality of flexible circuit boards are stacked together so that positions of their protrusions are aligned, the protrusions are each provided at a position where the partial wires corresponding among a plurality of flexible circuit boards are to be stacked together.