Motor Coil Substrate Layout for Circular Winding and Heat Dissipation
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Solution Overview
Problem
Existing coil substrates wound into cylindrical shapes often form polygonal cross sections due to orthogonal connection wiring directions, leading to potential interference with magnets and reduced heat dissipation, resulting in unstable motor performance.
Innovation Solution
A coil substrate design featuring flexible substrates with obliquely extending connection wirings relative to the longitudinal direction, preventing gap formation along the orthogonal direction and ensuring a cylindrical shape with a circular cross section when wound, thereby preventing short circuits and maintaining consistent gaps for improved heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If connection wirings extend in the orthogonal direction (perpendicular to longitudinal direction), then the coil substrate can be easily manufactured with simple wiring layout, but the wound motor coil substrate forms a polygonal cross section that interferes with magnets and reduces heat dissipation
Solution Approach 1:
The connection wirings are designed to extend obliquely at a specific angle (e.g., 45 degrees) relative to the longitudinal direction rather than perpendicular to it. This asymmetric arrangement ensures that when the flexible substrate is wound into a cylindrical shape, the connection wirings form a circular cross-section pattern that prevents polygonal formation, eliminates interference with magnets, and maintains consistent gaps for optimal heat dissipation while preserving manufacturing simplicity
2Device complexity
If connection wirings extend in the orthogonal direction, then the wiring structure is simple and easy to fabricate, but the wound structure forms gaps along the orthogonal direction that create polygonal cross sections
Solution Approach 1:
By configuring connection wirings to extend obliquely rather than perpendicular to the longitudinal direction, the patent transforms the wound cross-section from a polygonal shape (with straight edges and corners) into a circular shape. This asymmetric angular configuration ensures continuous coverage when wound, eliminating gap formation along orthogonal directions and achieving the desired cylindrical geometry with consistent radial gaps for heat dissipation
3Ease of manufacture
If the coil substrate is wound with orthogonal connection wirings, then manufacturing is straightforward, but the resulting polygonal cross section causes interference with magnets and reduces heat dissipation efficiency
Solution Approach 1:
The connection wirings are arranged to extend obliquely at a specific angle (e.g., 45 degrees) relative to the longitudinal direction. When the flexible substrate is wound into a cylindrical shape, this oblique arrangement creates a circular cross-section pattern that prevents polygonal formation. This eliminates interference with magnets positioned in the cylindrical space and maintains consistent radial gaps that facilitate efficient heat dissipation from the coils, while the winding process itself remains straightforward
Data Source
AI summary
A coil substrate includes a flexible substrate, terminals formed on one side of the flexible substrate such that the terminals are positioned in a longitudinal direction of the flexible substrate, coils each comprising a first wiring formed on a first surface and a second wiring formed on a second surface on the opposite side with respect to the first surface, and connection wirings formed on the flexible substrate such that the connection wirings include wirings connecting the terminals and the coils respectively and wirings connecting two of the coils respectively and that the connection wirings extend obliquely with respect to the longitudinal direction of the flexible substrate. The coil substrate is wound along the longitudinal direction of the flexible substrate around an axis extending in an orthogonal direction orthogonal to the longitudinal direction such that the coil substrate is formed into a cylindrical shape.