Segmented Flexible Circuit Stator for Large Motor Packaging
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Solution Overview
Problem
Existing flexible circuit boards for motors require large printing devices for long and large-area boards, complicating wire routing and reducing strength when thickness is reduced for size reduction.
Innovation Solution
A flexible circuit board design comprising first and second sub-circuit boards with parallel coil wires and connection terminals, allowing easy connection to an external circuit and eliminating the need for a long-length printing process, while maintaining strength through reinforcing wires and positioning protrusions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a long and large-area flexible circuit board is used to configure a stator for a large motor, then the motor size can be increased, but a printing device capable of printing large-sized flexible circuit boards is required, increasing device complexity
Solution Approach 1:
The flexible circuit board is divided into multiple short flexible circuit boards arranged in the longitudinal direction. Each short board can be printed with standard printing devices, avoiding the need for large-area printing equipment while still achieving the required total area for large motor stator configuration.
2Area of stationary object
If multiple short flexible circuit boards are arrayed to form a long flexible circuit board, then large motor configuration is enabled, but the number of connection points with external circuits increases, complicating wire routing
Solution Approach 1:
Multiple short flexible circuit boards are connected in series with connection portions that integrate the coil wires and connection terminals. This merging approach reduces the number of external connection points by combining multiple coil sets into a unified structure, simplifying wire routing to external circuits.
3Volume of moving object
If the thickness of the flexible board is reduced to decrease motor size, then the motor becomes more compact, but the strength of the flexible board decreases
Solution Approach 1:
A cover film is attached to the surface of the flexible board to create a composite structure. This allows the flexible board to maintain reduced thickness for compact motor size while the cover film provides the necessary strength and surface protection.
4Strength
If a cover film is attached to the flexible board to increase strength, then the board strength is improved, but the thickness of the flexible board increases
Solution Approach 1:
A thin cover film is used to provide surface protection and strength enhancement to the flexible board. The cover film is designed to be sufficiently thin to minimize thickness increase while providing adequate mechanical strength and protective functions.
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
Enables the formation of a stator compatible with large motors, easy connection to external circuits, and reduces thickness without compromising strength, leading to smaller and lighter electric motors.
Implementation Method 1
a connection setting set to a first connection setting, the connection setting being made between the predetermined number of the connection terminals and an external circuit to supply drive currents of the plurality of phases, the first connection setting being made in such a manner that a rotating magnetic field in a predetermined direction
Data Source
AI summary
A flexible circuit board includes a first sub-circuit board and a second sub-circuit board. The first sub-circuit board has a connection portion arranged at a first longitudinal end, and has a connection setting between connection terminals and external terminals of a plurality of phases U, V, W set to a first connection setting that generates a rotating magnetic field in a direction. The second sub-circuit board has a connection portion arranged at a second longitudinal end, and has a connection setting between connection terminals and external terminals of U, V, W set to a second connection setting that generates a rotating magnetic field in a direction. The first sub-circuit board and the second sub-circuit board are bent into a cylindrical shape with the first longitudinal end and the second longitudinal end adjacent to each other to form a stator for a rotating electric machine.