PCB Stator Substrate Materials for Recyclable Rotary Electric Machines
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Solution Overview
Problem
Conventional PCB stators in rotary electric machines, made from glass reinforced epoxy laminate, pose environmental and safety concerns due to toxic constituents and require burning for disposal, while also lacking sustainability and high durability.
Innovation Solution
A stator with a substrate made from thermoplastic, bio-based vitrimer, or bio-based thermoset materials, which are recyclable and potentially biodegradable, providing improved environmental sustainability and high durability, and optionally foamed for lightweight design, with electrically conductive traces built on or embedded within the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass reinforced epoxy laminate is used for PCB stator substrate, then structural strength and electrical insulation are improved, but environmental sustainability deteriorates due to toxic constituents and non-recyclability
Solution Approach 1:
The patent changes the material parameters of the substrate by replacing glass reinforced epoxy laminate with thermoplastic materials having different chemical compositions and physical properties. This substitution maintains mechanical strength while eliminating toxic constituents and enabling recyclability, thus resolving the contradiction between structural strength and environmental sustainability.
Solution Approach 2:
The patent employs composite material structures by combining thermoplastic substrates with copper windings and insulating layers. This composite approach allows optimization of each layer's properties - the thermoplastic provides structural strength and environmental benefits, while other layers contribute electrical and insulating functions, collectively resolving the contradiction.
2Stability of the object's composition
If conventional epoxy laminate is used for substrate, then manufacturing stability is improved, but recyclability deteriorates as burning is required for disposal
Solution Approach 1:
The patent changes the thermal and chemical parameters of the substrate material by adopting thermoplastics with defined melting temperatures (at least 150°C, preferably at least 200°C, more preferably at least 280°C). This parameter change enables the material to be remelted and recycled multiple times while maintaining manufacturing stability through controlled thermal processing.
3Temperature
If high-temperature thermoplastic is used for substrate, then heat resistance is improved, but processing difficulty increases due to higher melting temperature
Solution Approach 1:
The patent optimizes the thermal parameters of the thermoplastic material by selecting materials with melting temperatures in specific ranges (at least 150°C, preferably at least 200°C, more preferably at least 280°C). This parameter optimization achieves adequate heat resistance for motor operation while maintaining processability through established thermoplastic processing techniques.
Data Source
Figure 1a~3b
AI summary
Disclosed is a stator 10, 10', 10" for or of a rotary electric machine 1, 1', the stator configured as a PCB stator comprising a substrate 100 provided with one or more electrically conductive trace/s 110, 110', wherein the substrate is at least partially made of a substrate material comprising a thermoplast, a bio-based vitrimer and/or a bio-based thermoset. Further disclosed are a rotary electric machine comprising a rotor and such stator, and a household appliance comprising such rotary electric machine.