Stacking-Type Stator Using Multilayer PCB for Slim Motor Design
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Solution Overview
Problem
Conventional fan motors face challenges in reducing height, containing sufficient oil, and minimizing cost due to core-type stators and the need for expensive Hall sensors for rotor position detection, while also requiring complex winding structures and experiencing issues with coil breakage and heat generation during wireless charging.
Innovation Solution
A stacking-type stator using a multilayer printed circuit board (PCB) with alternately connected rotating and radial direction pattern portions, eliminating the need for multiple wiring pattern PCBs, integrating a sensing coil for sensorless motor driving, and employing a bridge structure for dead point prevention, allowing for a slim design and efficient torque generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If a core-type stator is used in conventional outer rotor type fan motors, then the motor structure is stable and reliable, but the height of the motor cannot be reduced
Solution Approach 1:
The invention extracts and removes the core-type stator structure from the motor design, replacing it with a coreless flat brushless motor structure. This extraction of the core component enables significant reduction in motor height while maintaining operational reliability through the alternative coreless design.
Solution Approach 2:
The invention inverts the conventional approach by adopting a coreless structure instead of a core-type structure. This inversion of the fundamental stator design enables the motor to achieve ultra-lightness and ultra-small size, particularly reducing height in the axial direction, while still providing stable and reliable operation.
2Quantity of substance
If the diameter of the bearing is limited in conventional designs, then the stator structure remains compact, but sufficient oil cannot be contained therein
Solution Approach 1:
The invention transitions from a radial dimension constraint to an axial dimension solution by采用 a coreless flat brushless motor structure. This dimensional change allows the bearing to contain sufficient oil for reliable operation without increasing the bearing diameter, as the oil containment space is reorganized in the axial direction rather than radially.
3Measurement precision
If a Hall sensor is used for rotor position detection, then accurate position detection is achieved, but the cost increases significantly
Solution Approach 1:
The invention implements sensorless motor driving methods that enable the motor to self-detect rotor position through back-EMF detection and other self-sensing techniques. This self-service approach eliminates the need for external Hall sensors, achieving accurate rotor position detection while significantly reducing manufacturing costs and component complexity.
Solution Approach 2:
The invention replaces the mechanical/electronic Hall sensor system with sensorless detection methods using electrical signal analysis. By detecting back-EMF and other electrical characteristics, the system achieves rotor position detection without physical sensors, substituting a complex sensing mechanism with a simpler electrical detection approach.
4Ease of manufacture
If a single Hall sensor is used to reduce cost, then the number of components is reduced, but the magnetic pole cannot be detected at the interface of rotor magnetic pole creating a dead point
Solution Approach 1:
The invention uses sensorless motor driving methods that can detect rotor position throughout the entire rotation cycle, including at magnetic pole interfaces where Hall sensors fail. The self-sensing technique continuously monitors back-EMF signals, ensuring reliable starting and operation without dead points, while maintaining the simplicity of using fewer components.
Solution Approach 2:
The invention implements continuous feedback through back-EMF detection that provides real-time rotor position information throughout the entire rotation cycle. This feedback mechanism ensures that the motor can detect magnetic pole positions even at interfaces where a single Hall sensor would create dead points, maintaining reliable starting and operation with minimal components.
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
The solution results in a slim, cost-effective, and reliable single-phase motor with enhanced torque generation, improved durability, and reduced manufacturing complexity, suitable for applications like wireless chargers, by utilizing a thin film stator and eliminating the need for separate Hall sensors.
Implementation Method 1
coil patterns which have a star shape in which a plurality of rotating direction pattern portions and a plurality of radial direction pattern portions are alternately connected
Implementation Method 2
integrating a sensing coil for sensorless motor driving
Data Source
AI summary
Provided is a stacking-type stator using a multilayer printed circuit board (PCB) in which torque generation can be maximized in an opposite rotor, and a single-phase motor and a cooling fan both using the same. The stacking-type stator includes: a multilayer printed circuit board (PCB) that is stacked and integrated with a penetration opening; and a coil pattern patterned on each layer of the multilayer PCB, wherein throughholes are formed to penetrate the multilayer PCB and connect the coil patterns, wherein the coil pattern comprises: inner and outer rotating direction pattern portions which are arranged in a circumferential direction at intervals along an inner circumference and an outer circumference concentrically with the penetration opening; and a radial pattern portion that interconnects the inner rotating direction pattern portion and the outer rotating direction pattern portion that are adjacent to each other and is disposed along the radial direction.