Motor Printed Circuit Board Coil Pattern Manufacturing
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Solution Overview
Problem
Conventional motor manufacturing methods require complex and expensive winding processes, leading to reduced structural rigidity, increased volume due to coil end turns, and potential short circuits during compression.
Innovation Solution
A method involving printed circuit boards (PCBs) where coil patterns are printed on multiple boards, connected three-dimensionally through bent side parts, eliminating the need for winding devices and simplifying the manufacturing process by forming cutting lines and coupling holes for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a winding machine is used to wind the coil around the stator, then the coil can be formed, but the manufacturing process becomes complex and expensive
Solution Approach 1:
The patent replaces the mechanical winding machine with a printing process. Coil patterns are directly printed on flexible circuit boards using conventional PCB printing techniques, eliminating the need for complex winding机械设备. This substitution transforms a mechanical operation into a printing operation, significantly simplifying the manufacturing process and reducing equipment requirements.
Solution Approach 2:
The patent uses printing to create a copy or representation of the coil structure on the circuit board. Instead of physically winding wire, the coil pattern is reproduced through printing processes, allowing the coil structure to be formed as a printed circuit pattern that can then be metallized to create the actual conductive path.
2Productivity
If the coil is wound on the divided stator to streamline the operation, then the winding process is simplified, but the structural rigidity is reduced
Solution Approach 1:
The patent divides the stator into multiple separate parts, each with its own circuit board containing coil patterns. These segmented stator parts can be manufactured independently and then assembled together, improving manufacturing efficiency while allowing each segment to maintain its own structural integrity through the rigid circuit board substrate.
Solution Approach 2:
The patent transitions from a two-dimensional planar circuit board to a three-dimensional assembled structure. Multiple flat circuit boards are stacked and connected through vertical connections to form a three-dimensional stator assembly, achieving both manufacturing simplicity and structural rigidity through the multi-dimensional configuration.
3Ease of manufacture
If the end turn space is included in the motor design, then the coil can be accommodated, but the motor volume is enlarged
Solution Approach 1:
The patent nests the coil patterns directly within the circuit board structure itself. The coil patterns are printed and metallized on the same circuit board that forms the stator, eliminating the need for separate end turn spaces. The coil structure is nested within the planar circuit board area, maximizing space utilization and reducing overall motor volume.
4Volume of stationary object
If the end turn is compressed to fit the coil, then the space is optimized, but short circuits may occur during compression
Solution Approach 1:
The patent replaces the mechanical compression process with a printing and metallization process. Instead of physically compressing and shaping wire ends, the coil patterns are directly printed and metallized in their final positions on the circuit board, eliminating the compression step that could cause short circuits while achieving the same space optimization.
Data Source
AI summary
A motor using a printed circuit board may include: a first base part forming a first circuit board on which a coil pattern is printed; a second base part forming a second circuit board on which the coil pattern is printed, the second base part spaced apart from the first base part; and a plurality of side parts forming side circuit boards on which the coil pattern is printed, the plurality of side parts connected to the first base part and the second base part, respectively, such that the coil pattern successively connects the first base part, the second base part, and the plurality of side parts.