Multi-Layer Motor Stator With Through Conductors
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Solution Overview
Problem
Conventional motor stators with flexible bases suffer from low structural strength, stability issues, and complex circuit layouts, making them unsuitable for miniaturized applications where space is limited and high power is required.
Innovation Solution
A motor stator design featuring a plurality of wiring layers with an electrical connection module that includes a through conductor penetrating multiple layers to connect winding modules, providing structural strength and stability while simplifying circuit layout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a flexible base is used to support wiring layers, then the motor stator can be miniaturized, but the structural strength and combination stability deteriorate
Solution Approach 1:
The motor stator is divided into multiple wiring layers, each supported by rigid boards rather than a single flexible base. This segmentation allows each layer to be independently supported by rigid structures, maintaining structural strength while enabling miniaturization through layered configuration.
Solution Approach 2:
The invention uses composite construction with rigid boards providing structural support and multiple wiring layers integrated therein. This composite approach combines the structural advantages of rigid materials with the electrical functionality of multiple wiring layers, achieving both miniaturization and structural integrity.
2Length of stationary object
If bridge portions are bent to align carriers axially, then the motor stator thickness is reduced, but the bridge portions may be damaged
Solution Approach 1:
Instead of bending the bridge portions to achieve axial alignment, the invention inverts the approach by using rigid boards with pre-defined carrier positions that naturally provide axial alignment without requiring bending. This eliminates the stress and damage risk associated with bending while achieving the same alignment objective.
Solution Approach 2:
The invention uses identical rigid board structures for each wiring layer, with carriers positioned at corresponding locations. This copying approach ensures consistent axial alignment across all layers without requiring individual bending adjustments, thereby preventing damage to connecting portions.
3Ease of manufacture
If bridge portions protrude radially to connect carriers, then the motor stator can be assembled, but additional radial area is required
Solution Approach 1:
The invention transitions from radial protrusion to axial integration by incorporating connecting circuits directly within the wiring layers and rigid boards. This dimensional change allows electrical connections to be made through the thickness of the layers rather than requiring radial extensions, thereby reducing the radial area while maintaining assembly feasibility.
Solution Approach 2:
The connecting circuits are nested within the wiring layers and rigid board structures, with conductors embedded in the insulation layers. This nesting eliminates the need for external radial protrusions, as all connections are contained within the compact layered structure, reducing the overall radial footprint.
4Ease of manufacture
If wiring modules are formed on only two opposite surfaces, then the circuit layout becomes complex, but the manufacturing process is simplified
Solution Approach 1:
The circuit layout is segmented across multiple wiring layers, with each layer containing specific circuit portions. This segmentation allows complex circuits to be distributed across several simpler layers, reducing the complexity on any single surface while maintaining manufacturing simplicity through standardized layer construction.
Solution Approach 2:
The invention utilizes the third dimension (layer thickness) to resolve circuit layout complexity. By distributing circuits across multiple wiring layers rather than confining them to two surfaces, the complex interconnections are organized in three-dimensional space, simplifying the two-dimensional layout on each individual layer while achieving the required circuit functionality.
Data Source
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AI summary
A motor stator comprising a plurality of wiring layers (1) and at least one electrical connection module (2) is disclosed. Each wiring layer (1) has an insulating base (11) and at least one winding module (14) formed on the insulating base (11). Each electrical connection module (2) has a thorough conductor (21) and at least one local conductor (22), with the thorough conductor (21) penetrating the plurality of wiring layers (1) and electrically connecting with at least one of the at least one winding module (14) of at least one of the plural wiring layers (1), with the at least one local conductor (22) penetrating at least one of the plural wiring layers (1), and with each local conductor (22) electrically connecting the winding modules (14) of at least two of the plural wiring layers (1).