PCB Stator Trace Layout for Single-Step Via Manufacturing
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Solution Overview
Problem
The manufacturing process of PCB stators for axial field electric machines is complex and costly due to repetitive operations, particularly when vias intersect traces, leading to inefficiencies and increased costs.
Innovation Solution
The design of PCB stators with conductive traces arranged to avoid intersections between vias and traces, allowing for a simplified manufacturing process that includes laminating, via drilling, and plating in a single step, regardless of the number of turns or phases, and incorporating a partial ring as a ground plane and heat sink.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If PCB stators are manufactured through repetitive etching, laminating, drilling and plating operations, then manufacturing precision and electrical integrity are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent applies preliminary action by designing the PCB stator with conductive traces arranged to avoid intersections with vias before manufacturing begins. This pre-planned trace routing prevents the need for complex repetitive operations during manufacturing, as the design itself eliminates the problem of via-trace intersections that would otherwise require multiple processing steps
Solution Approach 2:
The patent segments the manufacturing process into distinct operational phases where vias are drilled and plated in a single step before trace deposition. This segmentation allows each process step to be optimized independently, reducing overall complexity while maintaining precision
2Reliability
If PCB stators undergo multiple laminating, drilling and plating operations, then reliability and electrical performance are improved, but productivity decreases
Solution Approach 1:
The patent merges multiple manufacturing operations into a single streamlined process. Specifically, laminating, via drilling, and plating are combined into one continuous operation rather than being performed as separate repetitive steps, thereby increasing productivity while maintaining the necessary quality standards for electrical performance
Solution Approach 2:
The design incorporates preliminary action by pre-arranging conductive traces to avoid via intersections, which eliminates the need for subsequent corrective operations or additional processing steps that would reduce productivity
3Ease of manufacture
If conductive traces are arranged to avoid via intersections, then manufacturing complexity is reduced, but design complexity increases
Solution Approach 1:
The patent resolves the trace routing complexity by utilizing the third dimension (vertical layering) rather than attempting to route all traces in a single plane. By arranging conductive traces on different layers and using vias to connect them, the design achieves via-free trace routing in each layer while maintaining electrical connectivity, thereby simplifying manufacturing without excessive design complexity
Data Source
AI summary
An axial field rotary energy device can include a rotor having an axis of rotation and a printed circuit board (PCB) stator having PCB panels. Each PCB panel has conductive layers, each conductive layer has coils, and each coil has conductive traces. A radial portion of the conductive traces are arranged to form spaces so vias coupled to one phase do not intersect coils from another phase. The PCB stator can have a contoured outer ring that is a uniform distance from an inner edge thereof to the outer edges of the coils.