PCB Stator Winding Layout for Single-Step Axial Flux Motor Manufacturing
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Solution Overview
Problem
The manufacturing process of axial field electric machines with printed circuit board (PCB) stators is complex and costly due to repetitive operations such as etching, laminating, drilling, and plating, which can be simplified by optimizing PCB stator design features to eliminate unnecessary steps.
Innovation Solution
The design features of the PCB stator include coils with a number of turns that is a multiple of the number of phases, allowing for non-intersecting vias and parallel traces, which enables a single-step lamination, drilling, and plating process, reducing the manufacturing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional PCB stator designs are used with individual panel processing, then manufacturing precision can be maintained, but device complexity and manufacturing cost increase due to repetitive operations
Solution Approach 1:
The patent merges multiple PCB panels into a single integrated PCB stator structure. Instead of processing individual panels separately through etching, laminating, drilling, and plating operations, the invention combines these operations into a unified manufacturing process for the entire stator, eliminating repetitive steps and reducing overall complexity
Solution Approach 2:
The invention creates a universal PCB stator design that can serve multiple phases simultaneously. The single integrated structure incorporates winding patterns for all phases within one PCB assembly, allowing one manufacturing process to produce a complete multi-phase stator rather than requiring separate processing for each phase panel
2Productivity
If PCB stator panels are processed individually through multiple operations, then manufacturing precision is maintained, but productivity decreases due to repetitive processing steps
Solution Approach 1:
The patent combines multiple sequential manufacturing operations into a single integrated process. By designing the PCB stator as one unified structure rather than separate panels, all etching, laminating, drilling, and plating operations can be performed in one continuous manufacturing cycle, dramatically reducing total production time
Solution Approach 2:
The invention performs preliminary design optimization of the PCB winding patterns before manufacturing. By pre-configuring the trace layouts and via placements to accommodate all phases in a single structure, the design enables streamlined manufacturing without requiring post-processing or rework, thus accelerating production
3Loss of energy
If intersecting traces are used in PCB stator design, then space utilization improves, but eddy current losses increase due to trace intersections
Solution Approach 1:
The patent extracts and eliminates the harmful intersecting trace configurations from the PCB stator design. By redesigning the winding patterns to use only parallel non-intersecting traces, the invention removes the source of eddy current circulation while maintaining the necessary electrical connectivity for all phases
Solution Approach 2:
The invention applies different trace configurations to different regions of the PCB stator. Specifically, it uses parallel non-intersecting traces in regions where eddy currents would form, while utilizing available space efficiently through optimized trace routing that maintains local electrical requirements without creating harmful intersections
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a faster and more economical manufacturing process for PCB stators, reducing eddy current losses and enhancing machine efficiency by eliminating intersecting traces that cause eddy current circulation.
Implementation Method 1
selected ones of the conductive layers are coupled to plated vias that extend from one major surface of the PCB stator to an opposite major surface of the PCB stator
Implementation Method 2
each major surface of the PCB stator comprises a layer of a dielectric material that completely covers ends of the plated vias
Implementation Method 3
eliminating intersecting traces that cause eddy current circulation
Data Source
Figure 1~2
Figure 3A
Figure 3B~3C
AI summary
A motor includes a stator and a rotor having an axis of rotation and a magnet. The stator includes a PCB having PCB panels. Each PCB panel is assigned to one electrical phase. Each PCB panel has a pair of PCB layers. Each PCB layer includes coils, and each coil in each PCB layer of a PCB panel is circumferentially aligned with a corresponding coil in another PCB layer. One coil in one PCB layer is coupled to a corresponding coil in another PCB layer with a via. A number of turns in each coil is a multiple of a number of electrical phases configured for the PCB stator. In addition, the vias that connect two coils in a pair of PCB layers that belong to a same electrical phase do not intersect coils in PCB layers that belong to other electrical phases of the PCB stator. An axial field rotary energy device is disclosed, for example, the device including a printed circuit board (PCB) stator having PCB panels. Each PCB panel can include conductive layers. Selected ones of the conductive layers are coupled to plated vias that extend from one major surface of the PCB stator to an opposite major surface of the PCB stator. In addition, each major surface of the PCB stator can have a layer of a dielectric material that completely covers ends of the plated vias.