Flexible Circuit Board Layout for Stator Coil Heat Dissipation
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Solution Overview
Problem
Existing rotating electrical machines face challenges in efficiently dissipating heat generated by stator coils formed from flexible circuit boards, which can lead to increased temperature and reduced magnetic susceptibility, affecting motor performance.
Innovation Solution
A flexible circuit board design featuring continuous wires with alternating first and second partial wires connected via vias in a chain-like shape, with connection conductor portions along the long sides of the insulating sheet, allowing for efficient heat dissipation and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a stator coil is formed from a flexible circuit board to reduce weight, then the weight of the rotating electrical machine is reduced, but heat dissipation becomes inefficient leading to temperature increase and reduced magnetic susceptibility
Solution Approach 1:
The continuous wire is divided into multiple first partial wires and second partial wires that are arranged in an alternating pattern on opposite surfaces of the insulating sheet. This segmentation creates multiple distributed connection points via vias, which act as heat dissipation paths from the coil to the insulating sheet, effectively reducing temperature in the stator core while maintaining the lightweight flexible circuit board structure
Solution Approach 2:
The wire configuration transitions from a conventional planar arrangement to a three-dimensional alternating pattern where first partial wires and second partial wires are positioned on opposite surfaces of the insulating sheet. This spatial arrangement creates multiple heat dissipation pathways through the thickness of the insulating sheet, improving thermal management while maintaining the flexible circuit board's weight advantage
2Temperature
If continuous wires are formed on both surfaces of the insulating sheet connected via vias, then heat dissipation efficiency is improved, but the manufacturing complexity increases
Solution Approach 1:
The first partial wires and second partial wires are connected through vias to form a unified continuous wire that spans both surfaces of the insulating sheet. This merging creates an integrated structure where the alternating pattern of partial wires on opposite surfaces works together as a single continuous conductor, improving heat dissipation while maintaining manufacturing feasibility through a unified construction approach
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 design enables efficient heat dissipation, reduces weight, and maintains high magnetic susceptibility, improving energy efficiency and motor performance by simplifying the manufacturing process and preventing temperature rises in the stator core.
Implementation Method 1
each of the vias is placed in a connection conductor portion that extends from each of ends of the first partial wires and ends of the second partial wires that overlap with the insulating sheet interposed therebetween toward a closer long side of the two long sides of the insulating sheet
Data Source
AI summary
A flexible circuit board includes at least one continuous wire where first and second partial wires and second partial wires respectively formed on first and second main surfaces of a strip-shaped insulating sheet are connected alternately via vias and which includes first and second continuous portions that cross in a chain-like shape to form annular portions without electrical continuity to each other in a projection plan view seen in a normal direction of a main surface of the insulating sheet. Two ends of each first and second partial wires are respectively placed along two long sides of the insulating sheet. Each via is placed on a connection conductor portion that extends from each of ends of the first partial wires and ends of the second partial wires that overlap with the insulating sheet interposed therebetween toward a closer long side of the two long sides.