Flexible Coil Substrate Layout for Precise Winding Alignment
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Solution Overview
Problem
Existing motor coil substrates face challenges in maximizing the space factor of coils due to misalignment of coil positions when winding flexible insulating substrates, leading to inefficiencies in motor performance.
Innovation Solution
A coil substrate design featuring a flexible substrate with a first and second flexible substrate extending from the first, where coils are formed in a row such that specific coils partially overlap while others do not, allowing for precise alignment and increased space factor upon winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If coils are arranged in a row on a flexible insulating substrate, then the substrate can be wound to form motor coils, but misalignment of coil positions occurs during winding leading to reduced space factor
Solution Approach 1:
The flexible substrate is divided into a first flexible substrate and a second flexible substrate that extends from the first. Coils are arranged in rows on these segmented substrates, allowing independent positioning and alignment adjustment during winding to achieve precise coil alignment and maximize space factor
Solution Approach 2:
The patent transitions from a single-plane coil arrangement to a multi-layer stacked configuration by winding multiple flexible substrates. The first and second flexible substrates are wound to form inner and outer coils respectively, creating a three-dimensional coil structure that increases the space factor while maintaining alignment precision through the overlapping arrangement
2Quantity of substance
If multiple flexible substrates are stacked and wound to increase coil density, then the space factor improves, but alignment precision between inner and outer coils becomes difficult to maintain
Solution Approach 1:
The first and second flexible substrates are prepared with pre-defined coil patterns and overlapping arrangements before winding. The second flexible substrate extends from the first substrate in a configuration that pre-establishes the alignment relationship between inner and outer coils, ensuring precise alignment is achieved automatically during the winding process without requiring complex post-adjustment
Solution Approach 2:
The first flexible substrate forms the inner coil structure while the second flexible substrate forms the outer coil structure, with the second substrate extending from and wrapping around the first. This nested configuration allows the inner and outer coils to be precisely aligned through the overlapping arrangement, maximizing the space factor while maintaining alignment precision
Data Source
AI summary
A coil substrate includes a flexible substrate including a first substrate and a second substrate extending from the first substrate, and coils formed on the flexible substrate. The coils are positioned substantially in a row and include an m-th coil, an (m+1)-th coil, an (m+2)-th coil, an (m+3)-th coil, and an (m+4)-th coil. The (m+1)-th coil is positioned next to the m-th coil, the (m+2)-th coil is positioned next to the (m+1)-th coil, the (m+3)-th coil is positioned next to the (m+2)-th coil, the (m+4)-th coil is positioned next to the (m+3)-th coil, the m-th coil, the (m+1)-th coil, and the (m+2)-th coil partially overlap, and the m-th coil and the (m+4)-th coil do not overlap, where m is a natural number.