Monolithic PCB Stator Winding Design for Axial Field Motor
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Solution Overview
Problem
The manufacturing process of printed circuit board (PCB) stators for axial field rotary energy devices is complex and costly due to repetitive operations, particularly when PCB stators require splitting into panels that need to be processed individually through etching, laminating, drilling, and plating, with vias often intersecting coils across different phases, leading to inefficiencies and potential eddy current losses.
Innovation Solution
The design involves PCB stators with coils having a number of turns that is a multiple of the electrical phases, where vias connecting coils within the same phase do not intersect with coils of other phases, allowing for simplified manufacturing by laminating, drilling, and plating in a single step, and using parallel traces to prevent eddy current circulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If PCB stators are split into panels and processed individually through etching, laminating, drilling and plating operations, then manufacturing precision can be maintained, but device complexity and manufacturing time increase significantly
Solution Approach 1:
The patent merges multiple PCB panels into a single monolithic PCB stator structure. The design allows multiple phase windings to be integrated on one continuous PCB substrate with through-holes providing electrical connections between layers, eliminating the need to process and assemble separate panels while maintaining manufacturing precision through standardized PCB fabrication processes.
Solution Approach 2:
The monolithic PCB stator design serves multiple functions simultaneously: it provides structural support, electrical insulation, and electrical connections through its integrated multi-layer construction. The through-holes serve both as mechanical alignment features and as electrical conductors, reducing the need for separate components and assembly steps.
2Manufacturing precision
If PCB stators are split into panels requiring individual processing through etching, laminating, drilling and plating, then manufacturing precision is maintained, but productivity decreases due to repetitive operations
Solution Approach 1:
The patent combines multiple PCB panels into a single monolithic structure that can be manufactured in one continuous PCB fabrication process. This eliminates repetitive etching, laminating, drilling, and plating operations that would be required for multiple separate panels, thereby significantly increasing production speed while maintaining precision through standardized PCB manufacturing.
3Reliability
If vias connect coils in different PCB layers, then electrical connectivity is achieved, but eddy current losses increase when vias intersect coils of different phases
Solution Approach 1:
The patent applies different via configurations to different regions of the PCB stator based on local requirements. In regions where coils of different phases are adjacent, the design avoids placing vias that would create eddy current paths. Instead, electrical connectivity is achieved through carefully positioned vias that connect only within the same phase or through optimized routing that prevents eddy current formation, while maintaining necessary electrical connectivity.
4Adaptability or versatility
If standard PCB manufacturing processes are used for multi-panel stators, then manufacturing flexibility is maintained, but manufacturing cost increases due to repetitive operations
Solution Approach 1:
The patent combines multiple PCB panels into a single monolithic PCB stator that can be manufactured using standard PCB fabrication processes. This approach maintains manufacturing flexibility by utilizing conventional etching, laminating, drilling, and plating operations, while reducing costs by eliminating the need to repeat these operations multiple times for separate panels. The integrated design allows all features to be created in a single manufacturing run.
Data Source
AI summary
A motor includes a stator and a rotor having an axis of rotation and a magnet. The stator includes a PCB having PCB panels. Each PCB panel is assigned to one electrical phase. Each PCB panel has a pair of PCB layers. Each PCB layer includes coils, and each coil in each PCB layer of a PCB panel is circumferentially aligned with a corresponding coil in another PCB layer. One coil in one PCB layer is coupled to a corresponding coil in another PCB layer with a via. A number of turns in each coil is a multiple of a number of electrical phases configured for the PCB stator. In addition, the vias that connect two coils in a pair of PCB layers that belong to a same electrical phase do not intersect coils in PCB layers that belong to other electrical phases of the PCB stator.