Flexible Motor Coil Substrate for High Torque in Compact Motors
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing motors, particularly small motors, require improved torque performance.
Innovation Solution
A motor coil board with a flexible board and coils wound in a cylindrical shape, achieving a coil space factor of 50%-99% in cross section, ensuring high torque and forming a high-performance motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional coil structures are used in motors, then the motor structure is simple and easy to manufacture, but the coil space factor is low resulting in insufficient torque
Solution Approach 1:
The patent applies nesting by placing multiple coils within the stator tooth structure. The coil board is wound to form coils that are nested within the stator teeth, with multiple coils arranged in series along the axial direction. This nesting approach increases the coil space factor and torque without significantly complicating the overall motor structure.
Solution Approach 2:
The patent transitions from traditional planar coil arrangements to a three-dimensional configuration by winding the coil board axially within the stator teeth. The coil board extends in the axial direction and is wound to form coils that utilize the vertical space within the stator, effectively adding a dimensional aspect to the coil arrangement that increases space utilization.
2Force
If the coil space factor is increased to improve torque, then motor performance improves, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies preliminary action by pre-forming the coil board with the desired coil configuration before installation into the motor. The coil board is manufactured as a complete assembly with coils already wound and positioned, which simplifies the final assembly process and reduces the precision requirements during motor assembly. The coil board can be pre-assembled and tested separately.
Solution Approach 2:
The coil board itself acts as an intermediary component that simplifies the relationship between the coils and the stator structure. By using a flexible coil board as the intermediary, the complex coil windings can be easily installed and positioned within the stator teeth without requiring high-precision alignment during final assembly.
3Volume of moving object
If small motor size is reduced for compactness, then the motor becomes more compact, but the torque output decreases
Solution Approach 1:
The patent uses a flexible coil board that can be wound and shaped to fit within the limited space of small motors. The flexibility of the coil board allows it to conform to the stator tooth geometry and maximize the use of available space, thereby maintaining high torque output in a compact motor configuration.
Solution Approach 2:
The coil board is made from composite materials that combine flexibility with sufficient mechanical strength and electrical conductivity. This composite structure allows the coil board to be wound into compact configurations while maintaining the structural integrity and electrical performance needed for high torque output in small motors.
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 results in high torque and improved performance in both standard and small motors, with enhanced bonding strength and stability.
Implementation Method 1
a motor coil board... comprising a flexible board and a plurality of coils formed by wiring provided on the first face and the second face
Implementation Method 2
arranging the motor coil board on the inside of a cylindrical yoke, and arranging a rotary shaft and a magnet on the inside of the motor coil board
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
Provided are a coil substrate for a motor with which a motor having high torque and high performance can be obtained, and a motor formed by using the coil substrate for a motor. A coil substrate for a motor according to the present embodiment has a flexible substrate having a first surface and a second surface on the side opposite the first surface, and a plurality of coils formed by wiring provided to the first surface and the second surface, the coil substrate for a motor being formed into a cylindrical shape by being wound in a circumferential direction with a first longitudinal-direction end of the flexible substrate as a starting point, centered on an axis extending in an orthogonal direction that is orthogonal to the longitudinal direction. The occupancy ratio of the coil in a cross-section of the coil substrate for a motor is 50-99%.