JP2020088922A - Coil substrate, laminated coil substrate, motor coil substrate, and motor - Google Patents

Abstract

To provide a motor coil substrate with high space factor.SOLUTION: A coil substrate of the embodiment includes a flexible substrate and a gap formed between a plurality of coils formed on the flexible substrate and an adjacent coil. Then, the coil includes a center space SC, and a first wiring 51 and a second wiring 52 arranged around the center space SC. Distance (width) D1 of a first wiring group 51g, distance (width) D2 of a second wiring group 52g, distance (width) DS of the center space SC, and distance DG of the gap G are substantially equal. Then, the flexible substrate is folded so that parts of the adjacent coils are overlapped. Then, by arranging the folded flexible substrate around a magnet, a motor coil substrate of the embodiment is formed.SELECTED DRAWING: Figure 1

Description

The present invention relates to a coil substrate including a flexible substrate and a coil formed on the flexible substrate, a laminated coil substrate, a coil substrate for a motor, and a motor.

Patent Document 1 relates to an electric motor, and the electric motor includes a plurality of single coils made of wires.

JP, 2007-124892, A

[Problems of Patent Literature]
The electric motor of Patent Document 1 includes a plurality of single coils made of wires. The coil is made of wire. If the wire is thin, it may be difficult to wind the wire. The wire is believed to break. Since the coil is made of wire, it is considered difficult to increase the space factor. According to FIG. 6 of Patent Document 1, single coils are stacked. It is considered difficult to stack single coils made of wire with high positional accuracy.

A coil substrate according to the present invention includes a flexible substrate having one end and the other end opposite to the one end, and a plurality of coils formed on the flexible substrate and arranged from the one end toward the other end. And a gap formed between the adjacent coils. The coil is formed of a central space and wiring surrounding the central space, and the wiring includes a plurality of first wirings and a plurality of second wirings facing each other through the central space, Among the first wiring and the second wiring to be formed, the first wiring is close to the one end, each of the first wirings is formed substantially in parallel, and each of the second wirings is formed substantially in parallel. The first wiring and the second wiring are formed substantially parallel to each other, the first wiring group is formed by the plurality of first wirings, and the second wiring group is formed by the plurality of second wirings. And the gap is formed between the second wiring group of the mth coil and the first wiring group of the (m+1)th coil, and the first wiring group has a distance D1. , The second wiring group has a distance D2, the central space has a distance DS between the first wiring group and the second wiring group, the gap has a distance DG, and the distance D1. The distance D2, the distance DS, and the distance DG are substantially equal.

[Effect of Embodiment]
According to the embodiment of the present invention, the coil is formed by wiring. For example, the coil can be formed by the technique of a printed wiring board. Therefore, the wiring forming the coil can be made substantially rectangular. The occupancy of the coil can be increased. Further, by folding the flexible substrate, a part of the adjacent coils is overlapped. The coils can be stacked with high positional accuracy. The coil substrate for the motor is formed by winding the folded flexible substrate. Therefore, the space factor of the coil can be increased. The distance D1 of the first wiring group forming the coil, the distance D2 of the second wiring group, the distance DS of the central space, and the gap distance DG are substantially equal. Therefore, by folding the flexible substrate, the central space of the mth coil is substantially covered with the second wiring group of the (m+1)th coil. The space factor of the coil can be increased. A coil substrate for a motor having high efficiency can be provided.

1A is a schematic view of a motor, FIG. 1B shows a cross section of a motor coil substrate, FIG. 1C shows a laminated coil substrate, and FIG. 1D shows a motor coil. It is a schematic diagram of a board|substrate. 2A shows a coil substrate, and FIG. 2B shows a cross section of the coil. FIG. 3A shows the upper coil and FIG. 3B shows the lower coil. FIG. 4A shows a cross section of the laminated coil substrate, and FIG. 4B shows overlapping of the coils.

FIG. 1A is a schematic diagram of a motor 10 including a magnet 48 and the motor coil substrate 20 of the embodiment. The motor coil substrate 20 is arranged around the magnet 48 via the cavity AH. An example of the motor 10 is a DC motor. The motor 10 may further include a commutator, a brush and a housing (not shown). Although the coil substrate 20 rotates in the embodiment, the magnet 48 may rotate.

1B shows a cross section of the motor coil substrate 20 shown in FIG. In FIG. 1B, a flexible substrate 22 that forms the motor coil substrate 20 is schematically shown. FIG. 1C shows the folded flexible substrate 22. In the embodiment, the flexible substrate 22 is folded, and then the folded flexible substrate 22 is rolled into a tubular shape. Then, the cylindrical flexible substrate 22 is arranged around the magnet. For example, the number of times the folded flexible substrate 22 is wound is 1 or more and 5 or less.

2A and 3 show a coil substrate 201 for forming the motor coil substrate 20 of the embodiment. The coil substrate 201 is formed of a flexible substrate 22 having a first surface F and a second surface S opposite to the first surface F, and a plurality of coils C formed on the first surface F of the flexible substrate 22. There is. In FIG. 2A, the coil C is simplified.

FIG. 3A shows the first surface F of the flexible substrate 22 and the coil C formed on the first surface F. The coil C on the first surface F is referred to as an upper coil CF. FIG. 3B shows the second surface S of the flexible substrate 22 and the coil C formed on the second surface S. The coil C on the second surface S is referred to as a lower coil CS.

As shown in FIG. 3A, the flexible substrate 22 preferably has short sides 20S and long sides 20L. The upper coils CF are arranged along the long side 20L of the flexible substrate 22. The upper coils CF are arranged in a line from one end 20SL of the flexible substrate 22 toward the other end 20SR. The number of upper coils CF is N.

In FIG. 3A, the first upper coil CF1, the mth upper coil CFm, the (m+1)th upper coil CFm1, and the Nth upper coil CFn are drawn.

As shown in FIG. 3B, the lower coils CS are arranged along the long side 20L of the flexible substrate 22. The lower coils CS are arranged in a line from one end 20SL of the flexible substrate 22 toward the other end 20SR. The number of lower coils CS is N.

In FIG. 3B, the first lower coil CS1, the mth lower coil CSm, the (m+1)th lower coil CSm1 and the Nth lower coil CSn are drawn. m and N are natural numbers.

N is preferably 3 or more and 11 or less. Particularly, N is preferably 7.

The m-th lower coil CSm is formed immediately below the m-th upper coil CFm. The upper coil CF and the lower coil CS are formed substantially symmetrically with the flexible substrate 22 in between. The upper coil CF and the lower coil CS are connected by a through-hole conductor that penetrates the flexible substrate 22.

The coil C is formed by the technique of a printed wiring board. The wiring w forming the coil C is formed by plating. Alternatively, the wiring w forming the coil C is formed by etching a copper foil. The wiring w that forms the coil C is formed by the semi-additive method, the M-Sap method, or the subtractive method.

The wiring w forming the coil C of the embodiment is formed by the technique of a printed wiring board. Therefore, the cross-sectional shape of the wiring w is substantially rectangular. Since the cross section of the wire is a circle, according to the embodiment, the space factor of the coil can be increased.

The plurality of coils C formed on the flexible substrate 22 are formed at the same time. For example, the plurality of coils C are formed on the flexible substrate 22 by using a common alignment mark. Therefore, the position of each coil C is related.

As shown in FIG. 3, the coil C is formed of a central space SC and a wiring w surrounding the central space SC. The wiring w has an outer end OE and an inner end IE. The wiring w is formed between the outer end OE and the inner end IE. The wiring w forming the coil C is formed in a spiral shape. The center space SC is surrounded by the innermost wiring of the wiring w forming the coil C. The innermost wiring w of the plurality of wirings w is the inner wiring Iw. The outermost wiring w is the outer wiring Ow.

As shown in FIG. 3, the wiring w includes a plurality of first wirings 51 and a plurality of second wirings 52 that are opposed to each other via a central space. In one coil C, the first wiring 51 is close to the one end 20SL and the second wiring 52 is close to the other end 20SR. Each of the first wirings 51 is formed substantially in parallel. Each of the second wirings 52 is formed substantially in parallel. The first wiring 51 and the second wiring 52 are formed substantially parallel to each other. When the motor 10 is formed by the motor coil substrate 20 and the magnet 48 of the embodiment, the angle between the rotation direction of the motor 10 and the first wiring 51 is approximately 90 degrees. The wiring w further includes a third wiring 53 that connects the first wiring 51 and the second wiring 52. The third wiring 53 is bent.

In FIG. 2A, the wiring w is put together. The plurality of first wirings 51 form a first wiring group 51g. A second wiring group 52g is formed by the plurality of second wirings 52. A plurality of third wirings 53 forms a third wiring group 53g. A gap G is formed between the second wiring group 52g of the mth upper coil CFm and the first wiring group 51g of the (m+1)th upper coil CFm1. The first wiring group 51g has a distance D1, the second wiring group 52g has a distance D2, the central space SC has a distance DS between the first wiring group 51g and the second wiring group 52g, and the gap G has a distance DG. The distance D1, the distance D2, the distance DS, and the distance DG are substantially equal. The distance D1, the distance D2, the distance DS, and the distance DG are measured along a straight line perpendicular to the first wiring 51.

FIG. 2B shows a cross section of the wiring w and a side wall of the wiring w. The first wiring forming the outer wiring Ow in the first wiring group 51g is the outer first wiring 51Ow. The outer first wiring 51Ow has a side wall 51sw1 facing the one end 20SL. The first wiring forming the inner wiring Iw in the first wiring group 51g is the inner first wiring 51Iw. The inner first wiring 51Iw has a sidewall 51sw2 facing the central space SC.
The second wiring forming the outer wiring Ow in the second wiring group 52g is the outer second wiring 52Ow. The outer second wiring 52Ow has a side wall 52sw1 facing the other end 20SR. The second wiring forming the inner wiring Iw in the second wiring group 52g is the inner second wiring 52Iw. The inner second wiring 52Iw has a side wall 52sw2 facing the central space SC.
The distance D1 is the distance between the side wall 51sw1 of the outer first wiring 51Ow forming the mth coil and the side wall 51sw2 of the inner first wiring 51Iw forming the mth coil.
The distance D2 is the distance between the side wall 52sw1 of the outer second wiring 52Ow forming the mth coil and the side wall 52sw2 of the inner second wiring 52Iw forming the mth coil.
The distance DG is the distance between the side wall 51sw1 of the outer first wiring 51Ow forming the (m+1)th coil and the side wall 52sw1 of the outer second wiring 52Ow forming the mth coil.
The distance DS is the distance between the side wall 51sw2 of the inner first wiring 51Iw forming the mth coil and the side wall 52sw2 of the inner second wiring 52Iw forming the mth coil.

Each upper coil CF is connected to the connection line cL via the lower coil CS. The mth upper coil CFm is connected to the (m+1)th upper coil CFm1 via the connection line cL and the mth lower coil CSm. The Nth upper coil CFn is connected to the first upper coil CF1 via the connection line cL and the Nth lower coil CSn. In this way, the upper coil CF is sequentially connected by the connection line.

Each lower coil CS is connected to the connection line cL via the upper coil CF. The mth lower coil CSm is connected to the (m+1)th lower coil CSm1 via the connection line cL and the (m+1)th upper coil CFm1. The Nth lower coil CSn is connected to the first lower coil CS1 via the connection line cL and the first upper coil CF1. In this way, the lower coil CS is sequentially connected by the connection line.

In FIG. 3, the connection line cL is omitted. The connection line cL is formed of at least one of a through-hole conductor penetrating the flexible substrate 22, a conductor circuit on the first surface F, and a conductor circuit on the second surface S.

As shown in FIG. 3, the coil substrate 201 according to the embodiment may include the terminal substrate 24 and the terminals T formed on the terminal substrate 24. The terminal board 24 and the flexible board 22 supporting the coil C are formed by one flexible board 22.

The terminal T and the coil C are formed at the same time. The number of terminal substrates 24 is preferably the same as the number of upper coils CF. The number of terminals T is preferably the same as the number of upper coils CF.

As shown in FIG. 3, the coil substrate 201 can include a plurality of terminal wiring lines tL that connect the connection line cL and the terminal T. The terminal wiring tL includes a terminal wiring tL extending from a connection line cL connecting the mth upper coil CFm and the (m+1)th upper coil CFm1, an Nth upper coil CFn, and a first upper coil CF1. The terminal wiring tL extending from the connecting line cL to be connected is included.

In the coil substrate 201 of the embodiment, the m-th upper coil CFm and the m-th lower coil CSm are wound in the same way. The direction of the current flowing through the m-th upper coil CFm and the direction of the current flowing through the m-th lower coil CSm are the same. The winding method of the mth upper coil CFm and the (m+1)th upper coil CFm1 are opposite. The direction of the current flowing through the mth upper coil CFm and the direction of the current flowing through the (m+1)th upper coil CFm1 are opposite. The m-th upper coil CFm and the (m+2)-th upper coil CFm2 are wound in the same manner. The direction of the current flowing through the mth upper coil CFm and the direction of the current flowing through the (m+2)th upper coil CFm2 are the same.
The winding method of the coil C in the coil substrate 201 and the direction of the current flowing through the coil C in the coil substrate 201 are observed from the position on the first surface F.

The flexible substrate 22 is folded along the folding line BL. The coil substrate 201 is folded along the folding line BL. The folding line BL exists between the adjacent upper coils CF. As shown in FIGS. 2A and 3A, the folding line BL is arranged along the side wall 51sw1 of the outer first wiring 51Ow. The folding line BL is an extension of the side wall 51sw1. First, the flexible substrate 22 is folded such that the first surface F and the first surface F face each other. Next, the flexible substrate 22 is folded such that the second surface S and the second surface S face each other. Then, the flexible substrate 22 is folded such that the first surface F and the first surface F face each other. In this way, the flexible substrate 22 is folded such that the first surface F and the second surface S alternately face each other. As shown in FIG. 1C, the flexible substrate 22 is folded so that a staircase can be formed in one direction from the bottom surface B to the top surface Tt. The laminated coil substrate 202 shown in FIG. 1C is obtained.

As shown in FIG. 1C, the laminated coil substrate 202 has a bottom surface B and a top surface Tt opposite to the bottom surface B. The bottom surface B is the lowermost surface of the laminated coil substrate 202, and the top surface Tt is the uppermost surface of the laminated coil substrate 202.

FIG. 4 shows the overlap of the coils C. The lower coil CS is omitted. A cross section of the laminated coil substrate 202 positioned between X and Y shown in FIG. 1C is shown in FIG. In FIG. 4A, the wiring w is put together. The mth upper coil CFm and the (m+1)th upper coil CFm1 are observed from the position W on the top surface Tt of the laminated coil substrate 202. For example, FIG. 4B is obtained by projecting the mth upper coil CFm and the (m+1)th upper coil CFm1 onto one plane with light perpendicular to the first surface F.

As shown in FIGS. 4A and 4B, in the embodiment, the coil substrate 201 is folded such that the mth upper coil CFm and the (m+1)th upper coil CFm1 partially overlap with each other. .. In the laminated coil substrate 202, the (m+1)th upper coil CFm1 is positioned on the mth upper coil CFm so that the mth upper coil CFm and the (m+1)th upper coil CFm1 partially overlap with each other. .. The mth upper coil CFm and the (m+1)th upper coil CFm1 do not completely overlap. In the embodiment, by folding the flexible substrate 22, the coils C formed on the flexible substrate 22 can be stacked. Therefore, the coils C can be stacked with high accuracy. The space factor of the coil can be efficiently increased. The conductor resistance of the coil is low. A motor having high efficiency can be provided.

The distance (width) D1 of the first wiring group 51g, the distance (width) D2 of the second wiring group 52g, the distance (width) DS of the central space SC, and the distance DG of the gap G are substantially equal. Therefore, as shown in FIGS. 4A and 4B, the central space SC of the mth upper coil CFm is substantially covered with the second wiring group 52g of the (m+1)th upper coil CFm1. . Alternatively, the central space SC of the mth upper coil CFm is completely covered with the second wiring group 52g of the (m+1)th upper coil CFm1. As shown in FIG. 4A, the central space SC of the (m+1)th upper coil CFm1 is substantially covered with the first wiring group 51g of the (m+2)th upper coil CFm2. Alternatively, the central space SC of the (m+1)th upper coil CFm1 is completely covered with the first wiring group 51g of the (m+2)th upper coil CFm2. The space factor of the coil can be efficiently increased. When the central space SC is completely covered by the wiring group, the second wiring 52 forming the (m+1)th coil C is not located on the first wiring group 51g forming the mth coil C. When the central space is completely covered with the wiring group, the second wiring 52 forming the (m+1)th coil is not located on the second wiring group 52g forming the mth coil. When the central space is completely covered by the wiring group, the first wiring 51 forming the (m+1)th coil is not located on the second wiring group 52g forming the mth coil.

The winding method of the adjacent coils C in the coil substrate 201 is opposite. However, by folding the flexible substrate 22 between the adjacent coils C, each coil C is wound in the same way in the laminated coil substrate 202. The winding method of each coil C formed on the laminated coil substrate 202 is observed from the position W. The directions of the currents flowing through the coils C in the laminated coil substrate are the same. Since the laminated coil substrate 202 is wound, each coil in the motor coil substrate 20 is wound in the same manner. The directions of the currents flowing through the coils C in the motor coil substrate are the same. The torque of the motor can be increased. The direction of the current flowing through each coil C formed on the laminated coil substrate 202 is observed from the position W.

By winding the laminated coil substrate 202 as shown in FIG. 1(B), the motor coil substrate 20 is obtained. The laminated coil substrate 202 is wound around the cavity AH. An example of the shape of the motor coil substrate 20 is a cylinder.

The motor coil substrate 20 is arranged around the magnet 48 such that the top surface Tt and the magnet 48 face each other. Alternatively, the motor coil substrate 20 is arranged around the magnet 48 so that the bottom surface B and the magnet 48 face each other. The magnet 48 is arranged in the motor coil substrate 20. The motor 10 including the magnet 48 and the motor coil substrate 20 is completed. Since the folded flexible substrate 22 is arranged around the magnet 48, the positional relationship between the mth upper coil CFm and the (m+1)th upper coil CFm1 can be maintained. The motor 10 having high efficiency can be provided.

FIG. 1D is a schematic view of the motor coil substrate 20. FIG. 1D shows the rotation direction MR of the motor 10 and the coil C. In FIG. 1D, the coil C is drawn by a wiring group. The angle between the first wiring 51 and the rotation direction MR of the motor 10 is approximately 90 degrees.

By folding the coil substrate 201, the laminated coil substrate 202 is manufactured. By winding the laminated coil substrate 202, the motor coil substrate 20 is manufactured. According to the embodiment, the motor coil board 20 can be manufactured by the technique of the printed wiring board.

20 Motor Coil Substrate 48 Magnet 22 Flexible Substrate 24 Terminal Substrate 201 Coil Substrate 202 Laminated Coil Substrate T Terminal C Coil CF Upper Coil SC Center Space OE Outer End IE Inner End w Wiring tL Terminal Wiring

Claims (19)

A flexible substrate having one end and the other end opposite to the one end,
A plurality of coils that are formed on the flexible substrate and are arranged from the one end toward the other end;
A coil substrate comprising a gap formed between the adjacent coils,
The coil is formed of a central space and wiring surrounding the central space, and the wiring includes a plurality of first wirings and a plurality of second wirings facing each other through the central space, and forms each of the coils. Of the first wiring and the second wiring, the first wiring is close to the one end, each of the first wirings is formed substantially parallel, and each of the second wirings is formed substantially parallel. The first wiring and the second wiring are formed substantially parallel to each other, the first wiring group is formed of the plurality of first wirings, and the second wiring group is formed of the plurality of second wirings. The gap is formed between the second wiring group of the mth coil and the first wiring group of the (m+1)th coil, the first wiring group having a distance D1; The second wiring group has a distance D2, the central space has a distance DS between the first wiring group and the second wiring group, the gap has a distance DG, the distance D1 and the distance D1. The distance D2, the distance DS, and the distance DG are substantially equal.
m is a natural number. The coil substrate according to claim 1, wherein the distance D1, the distance D2, the distance DS, and the distance DG are measured along a straight line perpendicular to the first wiring. The coil substrate according to claim 1, wherein the wiring is formed in a spiral shape. The coil substrate according to claim 1, wherein a direction of a current flowing through the m-th coil is opposite to a direction of a current flowing through the (m+1)-th coil. The coil substrate according to claim 1, wherein among the first wirings forming the first wiring group, the outermost first wiring is an outer first wiring, and the outer first wiring is the outer wiring. It has a first side wall facing one end and a second side wall facing the other end. A laminated coil substrate formed by folding the coil substrate according to claim 5 along the first side wall. The laminated coil substrate according to claim 6, wherein the central space of the mth coil is substantially covered with the second wiring group of the (m+1)th coil. The laminated coil substrate according to claim 7, wherein the central space of the (m+1)th coil is substantially covered with the first wiring group of the (m+2)th coil. The laminated coil substrate according to claim 7, wherein the central space of the mth coil is completely covered by the second wiring group of the (m+1)th coil. The laminated coil substrate according to claim 8, wherein the central space of the (m+1)th coil is completely covered by the first wiring group of the (m+2)th coil. The coil substrate according to claim 4, wherein among the first wirings forming the first wiring group, the outermost first wiring is an outer first wiring, and the outer first wiring is the outer wiring. It has a first side wall facing one end and a second side wall facing the other end. A laminated coil substrate formed by folding the coil substrate according to claim 11 along the first side wall. The laminated coil substrate according to claim 12, wherein a direction of a current flowing through the mth coil and a direction of a current flowing through the (m+1)th coil are the same. A coil substrate for a motor, which is formed by winding the laminated coil substrate according to claim 6 in a tubular shape. A coil substrate for a motor, which is formed by winding the laminated coil substrate according to claim 12 in a tubular shape. A coil substrate for a motor according to claim 14;
A motor comprising: a magnet disposed in the motor coil substrate. A motor coil substrate according to claim 15;
A motor comprising: a magnet disposed in the motor coil substrate. The motor according to claim 16, wherein an angle between the first wiring and a rotation direction of the motor is approximately 90 degrees. The motor according to claim 17, wherein an angle between the first wiring and a rotation direction of the motor is approximately 90 degrees.

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