Folded Strip Coil Assembly for Planar Drive Fill Factor
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Solution Overview
Problem
Existing coil arrangements for multi-dimensional drives, particularly planar drives, face challenges in achieving high fill factor of conductive material and electrical conductivity while being cumbersome to assemble and prone to non-uniform field profiles due to the limitations of wound coils and PCB-based multi-layer boards.
Innovation Solution
A coil arrangement with a strip-like winding material, where the winding is formed as a folded structure with insulation layers to prevent flashover, allowing for increased fill density and electrical conductivity, combining the advantages of wound coils and multi-layer boards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wound coils are used, then electrical conductance is improved, but fill factor of conductive material deteriorates
Solution Approach 1:
The patent transitions from traditional three-dimensional wound coils to a two-dimensional planar coil structure. The coil is formed by folding a planar conductor strip into multiple layers, creating a compact planar winding structure that achieves high fill factor in the plane while maintaining electrical conductance through multiple parallel current paths.
Solution Approach 2:
The patent implements nested structure by folding the planar conductor strip into multiple layers that are stacked and interleaved. Each fold creates a nested arrangement where conductor layers are positioned one above another, maximizing the use of available space and achieving high fill factor while maintaining electrical connectivity.
2Quantity of substance
If PCB-based multi-layer boards are used, then fill factor of conductive material is improved, but device complexity and manufacturing cost worsen
Solution Approach 1:
The patent changes the physical form of the conductor from thick copper traces on PCB to thin flexible conductor strips that can be folded into three-dimensional structures. This parameter change allows the conductor to adapt to complex spatial arrangements while maintaining simplicity in manufacturing and assembly.
Solution Approach 2:
The patent divides the conductor into multiple separate folded strips, each forming an independent coil or conductor path. These segmented conductors can be independently manufactured and then assembled, simplifying the overall manufacturing process while achieving complex multi-layer configurations.
3Reliability
If wound coils are used, then electrical conductance is improved, but assembly complexity worsens
Solution Approach 1:
The patent performs preliminary folding and shaping of the conductor strips into their final three-dimensional coil configurations before assembly. The conductors are pre-formed with insulation layers and fold patterns that match the final assembly requirements, eliminating the need for complex on-site assembly operations.
Solution Approach 2:
The patent combines multiple functions into the folded conductor structure itself: the folding creates both the electrical winding pattern and the mechanical support structure, while insulation layers are integrated during the folding process. This merging eliminates separate assembly steps for structural support and electrical connectivity.
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 achieves a high fill factor of conductive material with high electrical conductance, enabling efficient and compact coil arrangements that can be easily produced and assembled, improving the accuracy and efficiency of multi-dimensional drives.
Implementation Method 1
A flashover between adjacent turns is prevented by means of an insulation layer
Implementation Method 2
Coil arrangements are used to generate the corresponding time-dependent magnetic fields
Data Source
AI summary
A coil assembly of a stator of a planar multi-dimensional drive includes at least one coil. The at least one coil includes a winding. The winding is electrically conductive and has a winding material. The winding is a structure of the winding material, which is folded at folding points and which has one or more windings.