JP4465647B2 - Multilayer coil and brushless motor using the same - Google Patents

Description

    The present invention relates to a small, thin and inexpensive brushless motor and a laminated coil used therefor.

Along with the downsizing of electronic devices, motors used in each electronic device are strongly demanded to be small and thin. As such a motor, for example, in Patent Document 1 shown as a first conventional example, a patterned conductor is spirally formed on an insulating substrate surface to form a sheet coil, and a plurality of the sheet coils are laminated and fixed. There has been disclosed a flat brushless motor in which a rotor having a permanent coil is disposed opposite to a rotor coil.
14 to 16, such a flat brushless motor has a three-phase eight-pole sheet-like coil 50 opposed to the magnetic pole surface of the rotor magnet 100 and is laminated and fixed to the stator yoke. Is forming. The one-phase coil is formed by one 8-pole flat coil, and the adjacent coil poles are wound so that the conductive wires are connected in series in a single stroke and have opposite polarities. These are concentrically stacked and fixed, and each coil is held by a coil holder 125 such as a yoke or a printed circuit board (PCB). The end of each coil is soldered to the pattern surface of the printed circuit board (PCB) 120. Connected. The sheet-like coil 50 is obtained by forming a coil pole 200 by applying a spiral pattern conductor on the surface of a thin insulating sheet 210 by etching or plating.

  Further, in Patent Document 2 shown as a second conventional example, a coil conductor pattern is formed on a green sheet obtained from a ceramic powder by, for example, a screen printing technique to form a coil sheet, and a plurality of these are laminated to form a through hole. Discloses a laminated coil for a brushless motor in which the coil conductor patterns are electrically connected to each other, and the coil conductor pattern and the green sheet are integrally fired.

Japanese Utility Model Publication No.58-172345 JP-A 64-59902

Such a conventional coil has the following problems. First, in the coil as in the first conventional example, a spiral pattern conductor is formed on the surface of a thin insulating sheet by etching, plating or the like to form a coil pole, which is laminated with a predetermined angle shifted in the circumferential direction. Although it is a coil, a process of forming a uniform adhesive layer between the layers is necessary, and in the adhesion process, a short circuit between the coil poles occurs due to misalignment between the layers, causing rotation unevenness and torque ripple. The problem that it is likely to occur, and resin materials such as polyimide and polyester are used as an insulating sheet, but mechanical strength is not expected in such a sheet coil itself, and it is generally arranged on a PCB or a yoke, It was difficult to reduce the size and thickness further.
In the coil of the second conventional example, a plurality of coil sheets are laminated on a green sheet substrate on which external terminal electrodes are formed. The thickness of the circular portion on which the coils are formed and the rectangle on which the external terminal electrodes are formed. The thickness of the part is different, the shape of the laminated coil is poor in productivity, and in order to obtain the mechanical strength of the external terminal electrode part, it is necessary to make the green sheet substrate with no coil conductor pattern thick. As a result, the thickness of the laminated coil increases, and the external terminal electrode portion increases the area of the laminated coil, resulting in an increase in the external dimensions of the brushless motor.
SUMMARY OF THE INVENTION An object of the present invention is to provide a high-strength, small and thin laminated coil and a brushless motor using the same, which are excellent in motor efficiency such as rotation unevenness and torque ripple, and have high productivity.

A first invention is a laminated coil for an n-phase motor (n is a natural number of 2 or more) in which a plurality of coil poles made of a coil formed of a conductor pattern are integrated in a laminated body formed by laminating insulator layers. The laminated coil has an input terminal and an output terminal formed on the outer surface of the laminated body, a first connection line that connects the input terminal and the coil pole, and a second coil that connects the in-phase coil pole in series. A connection line is provided, the first connection line and the second connection line are formed of a conductor pattern in the laminate, and the coil pole is sandwiched between the first connection line and the second connection line It is the laminated coil formed in the insulator layer. The number of coil poles is a multiple of n, and the number of coil poles for each phase is preferably equal. The number of phases n of the motor can be selected from two or more natural numbers, but if n is set to 2 or 3, the number of coils can be limited to the number that can provide the minimum necessary motor output from the viewpoint of miniaturization. Stable motor characteristics can be obtained.
A substantially central portion of the laminate has a through hole in which a rotating shaft and / or bearing of a brushless motor is disposed, and the first conductor is surrounded by an annular conductor portion and the annular conductor portion that surround the through hole. It is preferable that the first conductor portion to be connected to the terminal and the second conductor portion to be extended from the annular conductor portion and to be connected to the coil pole. And it is also preferable to form the said input terminal, an output terminal, and a 1st connection line on one main surface of a laminated body. In addition, the second connection line is preferably configured to have two arc-shaped portions formed on the circumferences having different radii and a radial portion connecting the two arc-shaped portions.
In the laminated coil of the present invention, the coils constituting the multi-phase coil poles are formed on the same layer on one side, but the coils constituting the in-phase coil poles are not adjacent to each other and around the motor rotation axis. They are arranged symmetrically by 180 ° and are connected to each other via a second connection line. With this configuration, the number of turns of the coil pole can be increased and the distance between each coil pole and the permanent magnet of the rotor can be made substantially the same, so that motor characteristics can be improved. . In order to obtain a stable rotational state of the motor, it is desirable that the total number of coil poles of each phase in the laminated coil is the same for each phase.

The center of the through hole formed in the substantially central portion of the laminate substantially coincides with the center of the rotor shaft.
Therefore, if the annular conductor portion of the second connection line is arranged so as to surround the through hole, the rotational performance of the motor is not hindered. Then, if the second conductor portion for connecting to the coil pole and the first conductor portion for connecting to the input terminal are formed to extend radially from the annular conductor portion, the effective coil length is slightly increased. Increases the motor performance.
In the present invention, the input terminal, the output terminal, and the first connection line are formed on one main surface of the laminate to facilitate connection with a printed circuit board (PCB). The input terminal and the output terminal are preferably LGA (Land Grid Array) and BGA (Ball Grid Array), respectively.

A second invention is a laminated coil for a three-phase motor in which a coil pole made of a plurality of coils formed by a conductor pattern is integrated with a laminated body formed by laminating insulator layers, and the laminated body is a rectangular flat plate The laminated coil is formed in the shape of each of one input terminal and three output terminals formed at different four corners of the same main surface of the multilayer body.
Since the coil pole is formed in an annular shape around the motor rotation shaft, the laminated coil may be formed in an annular shape. However, in order to form the annular shape, an additional means such as punching with a die is required, and it is difficult to singulate. However, according to the present invention, as will be described later, it is easy to form individual laminated coils from a laminated substrate containing a plurality of laminated bodies. And if the input terminal and the output terminal are formed at the four different corners of the main surface so as not to overlap with the coil pole in the stacking direction on the same main surface of the rectangular flat laminate, it is possible to substantially increase the size of the stacked coil. In addition, it is preferable without deteriorating the motor performance. Furthermore, since the input / output terminals can be formed relatively large, the terminal connection strength with the PCB can be improved, and the space of the laminate in which no coil pole is formed can be used effectively.

In the first or second invention, the coil pole is formed by connecting a plurality of coils formed in a plurality of insulator layers and overlapping in the stacking direction, and is wound clockwise at least from the inner circumference side to the outer circumference side. 1 coil and a second coil wound clockwise from the outer peripheral side to the inner peripheral side, and the first coil and the second coil are connected by a through-hole formed in the laminate. Therefore, it is preferable that the first coil and the second coil have the same winding direction.
If comprised in this way, since a current is applied to the first coil and the second coil in a fixed direction, it operates as one coil pole, and the number of turns of the coil pole can be increased. High torque can be achieved.
The coil poles of different phases are preferably arranged at equiangular intervals around the motor rotation axis, and the coil poles of the same phase are preferably arranged at a rotationally symmetric position at 180 ° with respect to the rotation center of the motor rotation axis. If coil poles of substantially the same size are arranged at equiangular intervals around the motor rotation axis, the back electromotive force of each coil pole is generated symmetrically with respect to the motor rotation axis. Can be improved.
The coil is preferably a fan-shaped spiral coil, and the opening angle is preferably 55 ° or less around the rotation axis of the motor. When the fan-shaped spiral coil is arranged around the rotation axis of the motor as described above, the line portion extending radially around the rotation axis becomes a coil effective length that contributes to the torque characteristics, and high torque can be obtained. The opening angle of the spiral coil is appropriately set according to the width of the conductor pattern constituting the spiral coil, the number of coils, and the total number of motors. If a three-phase motor has a 6-pole structure, the upper limit of the opening angle is set. Is preferably set to 55 ° or less.

  A third invention is a motor using the laminated coil according to any one of the first and second inventions, wherein the laminated coil is used as a stator, and the laminated coil is adjacent to different magnetic poles. This is a brushless motor disposed opposite to a rotor having a permanent magnet through a magnetic gap. And in this invention, it is preferable to comprise so that the electric signal control part which supplies an electric current periodically may be provided for every coil pole of a different phase of a laminated coil.

  According to the present invention, it is possible to provide a small and thin laminated coil and a brushless motor using the same which are rich in mass productivity and have no problems such as uneven rotation and torque ripple.

(First embodiment)
Hereinafter, a laminated coil and a brushless motor using the same according to an embodiment of the present invention will be described.
FIG. 1 is a perspective view of a laminated coil according to an embodiment of the present invention, and FIG. 2 is an exploded view showing an internal structure thereof. This laminated coil is formed by printing a conductive paste mainly composed of Ag, Cu or the like on a green sheet having a thickness of 20 μm to 200 μm made of a ceramic material (LTCC material) that can be fired at a low temperature to form a desired conductor pattern, A plurality of coil poles are integrated by appropriately laminating and firing green sheets having a conductor pattern. The width of the conductor pattern forming the coil pole is approximately 100 μm to 400 μm.

An example of the manufacturing method of the laminated coil which concerns on this invention is demonstrated using FIG.9 and FIG.10.
First, by a known sheet forming method such as a doctor blade method, a ceramic slurry made of ceramic powder, a binder, and a plasticizer is applied on a carrier film made of a polyethylene terephthalate film with a uniform thickness, and several tens μm to several hundreds A green sheet of μm is formed. Then, the dried green sheet is cut into a predetermined size with the carrier sheet attached. The ceramic powder can be sintered at 1000 ° C. or lower, for example, Al ₂ O ₃ as a main component, and low-temperature sintering containing at least one of SiO ₂ , SrO, CaO, PbO, Na ₂ O and K ₂ O as a multicomponent. In another example, the dielectric material is a low-temperature sinterable dielectric material containing Al ₂ O ₃ as a main component and at least one of MgO, SiO ₂ and GdO as a multicomponent. In another example, a low-temperature-sinterable magnetic ceramic material containing at least one of Bi ₂ O ₃ , Y ₂ O ₃ , CaCO ₃ , Fe ₂ O ₃ , In ₂ O ₃ and V ₂ O ₅ is provided. The ceramic component is devised to be sintered at low temperature.
In this embodiment, the main component is composed of oxides of Al, Si, Sr, and Ti, and Al, Si, Sr, and Ti are converted into Al ₂ O ₃ , SiO ₂ , SrO, and TiO ₂ , respectively, and a total of 100 masses. %, Al ₂ O ₃ converted to 10 to 60% by mass, SiO ₂ converted to 25 to 60% by mass, SrO converted to 7.5 to 50% by mass, TiO ₂ converted to 20% by mass or less Al, Si , Sr, Ti, and a dielectric ceramic containing 0.1 to 10% by mass of Bi in terms of Bi ₂ O ₃ as a subcomponent with respect to the total of 100% by mass. The basic characteristics of this dielectric ceramic are a dielectric constant of 7 to 9, and a three-point bending (sample shape length 36 mm, width 4 mm, thickness 3 mm, fulcrum distance) according to the bending strength test method defined in JIS R 1601. 30 mm) has a bending strength of 240 MPa or more, a Young's modulus of 110 GPa or more, and the LTCC material has a high bending strength and a Young's modulus.

A coil (not shown), input / output terminals and the like to be described later are formed on such a green sheet by a conductor pattern, and further laminated and pressure-bonded in a predetermined order to obtain a flat laminate 300 having a thickness of approximately 0.4 mm. did. A through hole (not shown) is formed in the green sheet, and a conductor pattern between the sheets is appropriately connected so as to function as a coil pole.
Thereafter, a portion serving as the rotation center of the motor rotation shaft of the laminate was punched out by a mold, or laser processing was performed to form a through hole 10 having a diameter of 2 mm.
Then, a plurality of divided grooves parallel to each other and a plurality of divided grooves 320 perpendicular to the divided grooves 320 were formed on the main surface of the flat laminate with a steel blade so as to have a depth of approximately 0.1 mm. The depth of the dividing groove is appropriately set in the range of 50 μm to 300 μm from the viewpoint of easiness of dividing and handling. Thereafter, the flat molded body was degreased and sintered to obtain a laminated substrate 300 (an assembly of laminated coils) of 65 mm × 60 mm × 0.3 mm. Input / output terminals of laminated coils are formed on the outer surface of the laminated substrate 300, and Ni plating and Au plating are applied thereto by electroless plating. After the plating process, it was divided along the divided grooves to obtain a laminated coil 1 for a brushless motor having an outer dimension of 8 mm × 8 mm × 0.3 mm shown in FIG.
In addition, a constraining layer such as a ceramic layer that does not sinter at 1000 ° C. or less such as Al ₂ O ₃ is provided on both main surfaces of the laminated body and sintered to suppress planar shrinkage, and a laminated coil for a brushless motor It is also preferable to do this.

Next, the internal structure of the laminated coil will be described in the order of lamination with reference to FIG. This laminated coil is a laminated coil for a brushless motor using a three-phase driving power source, and has an equivalent circuit shown in FIG.
First, second connection lines 300a, 300b, and 300c for connecting in-phase coil poles are formed in the lowermost first layer. These second connection lines are arranged at equiangular intervals around a motor rotation shaft, which will be described later, and are formed by two arcuate portions centering on the motor rotation shaft and radially formed from the center of the motor rotation shaft. It has a radial part connecting the two arcuate parts.
In this embodiment, the second connection line is configured as described above, and the in-phase coil poles arranged at the rotationally symmetric position at 180 ° are connected to the rotation center of the motor rotation shaft. By arranging the two arcuate portions on the circumference around the motor rotation axis, the torque characteristics can be improved to a slight extent without hindering the rotation characteristics of the motor.
In addition, the second connection line is formed inside the laminate, but may be formed by printing or transferring a conductive paste on the main surface of the laminate, and in that case, at least one layer is formed. Since the number of green sheets can be reduced, it is preferable because the laminated coil can be made thin, although it is slight.

A second layer on which a plurality of coils are formed is stacked on the first layer. The coils are arranged at equiangular intervals around the motor rotation shaft to form a multi-phase coil pole. FIG. 4A shows an enlarged plan view of a plurality of coils formed in the second layer. In this embodiment, six coils 251g, 252g, 253g, 251h, 252h, and 253h, which are three-phase coil poles, are formed on the same layer at intervals of 60 °.
The six coils are composed of first coil patterns 251h, 252h, and 253h and second coil patterns 251g, 252g, and 253g. The first coil patterns 251h, 252h, and 253h are clocks from the outer peripheral side to the inner peripheral side. And has through-hole portions (indicated by black circles in FIG. 2) for connecting to the second connection line at the outer peripheral end portion, and the second coil patterns 251g, 252g, and 253g are inward from the outer peripheral side. A through-hole portion is formed on the inner peripheral end portion so as to be connected to the second connection line.
As shown in FIG. 4A, the first coil patterns 251h, 252h, 253h and the second coil patterns 251g, 252g, 253g are alternately arranged around the motor rotation axis. The first coil patterns 251h, 252h, and 253h and the second coil patterns 251g, 252g, and 253g are all wound clockwise from the outer peripheral side to the inner peripheral side. Called the second coil.
In the present embodiment, the coil pattern at a rotationally symmetric position of 180 ° with respect to the motor rotation axis is connected in series by the second connection line to form a coil pole having the same phase. That is, the first coil pattern 251h and the second coil pattern 251g are connected by the second connection line 300a, and the first coil pattern 252h and the second coil pattern 252g are connected by the second connection line 300b. The first coil pattern 253h and the second coil pattern 253g are connected by the second connection line 300c, and each constitutes a coil pole. That is, the connection line 300a is the middle point of the second phase coil pole 61 shown in FIG. 3, the connection line 300b is the middle point of the first phase coil pole 60, and the connection line 300c is the middle point of the third phase coil pole 62. Each point is composed.

A third layer in which a plurality of coils are formed is disposed on the second layer. In this embodiment, as shown in FIG. 4 (b), the plurality of coils are six coils 251e serving as three-phase coil poles formed on the same layer at intervals of 60 ° around the motor rotation axis, 252e, 253e, 251f, 252f, and 253f, which are spiral coils each wound four turns.
The third coil patterns 251f, 252f, and 253f wound in the clockwise direction from the inner circumference side to the outer circumference side in the third layer are the first coil patterns 251h, 252h, and 253h (outer circumference side) formed in the second layer. To the inner peripheral side) and overlaps in the stacking direction. Further, the fourth coil patterns 251e, 252e, 253e (which are wound clockwise from the inner peripheral side to the outer peripheral side) formed on the third layer are the second coil patterns 251g formed on the second layer. , 252g and 253g (which are wound clockwise from the outer peripheral side to the inner peripheral side) overlap in the stacking direction. Corresponding coils in the second layer and the third layer are connected in the same winding direction via through-hole portions, respectively.
The third coil patterns 251f, 252f, and 253f and the fourth coil patterns 251e, 252e, and 253e are all wound clockwise from the inner periphery side to the outer periphery side. This is called 1 coil.

The fourth layer coil is configured substantially the same as the second layer coil, and the fifth layer coil is configured substantially the same as the third layer coil.
The spiral coils of the same phase formed in the second to fifth layers and overlapping in the stacking direction are, for example, the first coil wound in the clockwise direction from the inner peripheral side to the outer peripheral side when focusing on the coil patterns 251a, 251c, 251e, and 251g. Coil (251a), a second coil (251c) connected to the outer peripheral end of the first coil (251a) and wound clockwise from the outer peripheral side to the inner peripheral side, and the second coil (251c) The first coil (251e) wound in the clockwise direction from the inner peripheral side to the outer peripheral side and connected to the outer peripheral end of the first coil (251e) and connected from the outer peripheral side to the inner peripheral side Since the second coil (251g) wound in the clockwise direction is configured to have the same winding direction, a current is applied in a fixed direction to the first coil and the second coil.
In this embodiment, each coil has 4 turns, and the same-phase coil poles formed in different areas in a plane are connected to increase the number of turns of the coil per phase to 32 turns. High torque of the motor can be achieved. The number of turns of the coil can be easily adjusted by increasing or decreasing the number of layers on which the coil is formed.

Next, the detailed structure of the coil will be described. FIG. 5A shows the first coil pattern 251h formed in the second layer, and FIG. 5B shows the third coil pattern 251f formed in the third layer.
In this embodiment, each coil is a spiral coil wound four times. In order to improve torque performance, it is desirable to increase the number of turns, but even if an attempt is made to increase the number of coil turns by reducing the width of the conductor pattern that constitutes the coil, the DC resistance increases accordingly. Depending on the number of phases of the motor and the restrictions on the coil formation area depending on the external dimensions, 2 to 6 turns are appropriate.
The shape of the coil is preferably a fan shape. The opening angle θ of the coil is determined by the number of phases of the motor, the number of coils, and the like, and is appropriately set so as to obtain an appropriate number of coil turns so as not to contact the adjacent coil. . Furthermore, as an example of a preferred configuration of the coil, there is a coil shown in FIG. In this way, if the coil line portion (coil effective length L) that contributes to the torque characteristics about the rotation axis extends radially, the generated force most efficiently acts on the rotation of the motor to obtain high torque. This is preferable.
A circumferential portion that does not contribute to the torque characteristics of the coil is formed in an arc shape along the center circumference of the motor rotation shaft so as not to hinder the rotational performance of the motor.

Further, as shown in the AA ′ cross-sectional view of the laminated coil in FIG. 6, coils of the same phase overlapping in the stacking direction are arranged in a staggered manner and stacked in a staggered manner so as not to overlap as much as possible in the stacking direction. Is preferred.
If the distance between adjacent coils in the stacking direction is narrow and the coils are placed so that they overlap in the stacking direction and stacked and crimped, the coil will not be deformed or distorted, and will not be the part where the coil is formed. There may be a case where a uniform pressure does not act on the portion, and as a result, delamination (delamination) and minute cracks occur. Therefore, by configuring as described above, the collapse and distortion of the coil are reduced, and the occurrence of delamination and the like is suppressed.
Further, since the green sheet is more easily deformed than the coil conductor, when the coils are stacked in a staggered manner, the coil patterns 251d, 251h, 251h, and the coil patterns 251d, 251h are focused on the coil patterns 251d, 251h, for example. since the coil pattern is so pushed during crimping green sheets existing between, it can be formed narrow between them. Therefore, the coil is formed in a substantially dense state, and the conductor space factor can be improved.

On the sixth layer, which is laminated on the upper layer, the same conductive paste as that for forming the coil is printed to form the first connection line connecting the input terminal IN, the output terminals OUT1 to OUT3, and the coil pole. did. The first connection line is an annular conductor portion 210 formed so as to surround the through hole 10 formed in a substantially central portion of the multilayer body, and a first conductor that connects the annular conductor portion and the input terminal. Part 200 and second conductor parts 201a to 201c extending from the annular conductor part 210 and connected to the coil pole.
In this way, as shown in FIG. 8 by the two-dot broken line, the connection state between the coils is shown, and the first phase coil pole 60 arranged between the input terminal IN and the output terminal OUT1 is formed by the coils 252a to 252h. A second-phase coil pole 61 disposed between the terminal IN and the output terminal OUT2 is formed by the coils 251a to 251h, and a third-phase coil pole 62 disposed between the input terminal IN and the output terminal OUT3 is defined as the coils 253a to 253a. Formed in 253 h.
The center of the through hole 10 formed in the substantially central portion of the laminate substantially coincides with the center of the rotor shaft. The through hole 10 is formed by punching the laminated body with a mold or laser processing, but is formed in a process different from the process of forming the coil, input / output terminals, etc., so that the through hole has a desired position. May be off. In such a case, as shown in FIG. 7, if the annular conductor portion 210 is formed so as to surround the through hole, the positional deviation in the formation of the through hole between the through hole center 410 and the annular conductor portion center 400 is reduced. In addition to being easy to confirm, if each center position is measured by a measuring device such as a three-dimensional measuring device, the amount of deviation can be easily quantified. As a result, it is possible to easily and quantitatively determine the quality of the laminated coil.
As described above, an 8 mm × 8 mm × 0.3 mm laminated coil for a brushless motor was produced. In addition, it is also within the scope of the present invention to form a coat layer with overcoat glass on the main surface of the laminated coil.

(Second embodiment)
In this embodiment, an example of a brushless motor configured using the laminated coil of the present invention is shown. The brushless motor shown in FIG. 11 includes a first rotor 101a in which an annular magnet 100 in which N poles and S poles in a large number of sets shown in FIG. A rotating shaft 130 coupled to the center of the first rotor 101a, a stator 125 including the first rotor 101a and a laminated coil 1 that is disposed via a predetermined magnetic gap and applies an electromagnetic force; And an electric signal controller for periodically supplying a drive current to the coil pole 50 formed in the laminated coil 1, and a circuit pattern electrically connected to input / output terminals formed in the laminated coil 1 is formed. A PCB 150 is fixed to the stator 125 via a bushing so that the first rotor 101a rotates smoothly, and a bearing 150 that supports the rotating shaft connected to the first rotor 101a is provided. Example was 3 are those upcoming using the driving power source. Since the laminated coil 1 used in the present embodiment is the same as that disclosed in the first embodiment, the description thereof is omitted. The annular magnet 100 used here includes rare earth sintered magnets such as Nd—Fe—B sintered magnets and Sm—Co sintered magnets, and rare earth bonds such as Nd—Fe—B, Sm—Fe—N, and Sm—Co. A permanent magnet material having a high holding power such as a magnet or a ferrite sintered magnet is used. Preferably, the magnet thickness can be reduced by using a permanent magnet material having an intrinsic coercive force iHc higher than the residual magnetic flux density Br. As the shape of the annular magnet 100, a ring shape, a sector shape, a circular shape, or a rectangular shape obtained by dividing the ring can be used.

A drive current is supplied from the electric signal control unit to the coil pole 50 formed in the laminated coil 1 to generate a magnetic field. This magnetic field acts on the magnetic field of the annular magnet 100 of the first rotor 101a to generate an electromagnetic force. As a result, torque is generated between the first rotor 101a and the stator 125, and as a result, the first rotor 101a rotates by a predetermined angle. And the 1st rotor 105a rotates continuously by applying the drive current by the said electric signal control part to the coil pole of each phase one by one.
Further, the laminated coil 1 may be mounted with a land of the magnetic pole sensor of the first rotor 101a. In this magnetic pole sensor, a coil pole corresponding to the position of the magnetic pole of the rotor is excited to obtain a rotational force in a certain rotational direction, but a Hall element is often used. A line pattern for connection between the Hall element and the PCB on which the circuit pattern is formed can be formed in the laminated coil 1. Further, an FG (Frequency Generator) coil may be configured inside or on the main surface of the laminated coil 1, or a hall element may be arranged by providing a cavity in the laminated coil 1. With this configuration, a thin and high-output motor can be obtained without increasing the magnetic gap between the first rotor 101a and the stator 125.

Since the input / output terminals formed in the laminated coil 1 are formed on one main surface, they can be directly mounted on the PCB, and electrical connection with the circuit pattern is easy. Further, since the input / output terminals are formed at the four corners on one main surface, they can be mounted and connected around the through hole 135 formed in the PCB. The laminated coil 1 can be thinly formed by laminating the coils, and the ceramic material used therefor has high bending strength and Young's modulus, so that it has sufficient strength even if it is thinly connected to the periphery. Can be implemented. Therefore, the rotor can be provided close to the PCB, and the motor can be made thin.
In this embodiment, the PCB is used. However, it is within the scope of the present invention that the laminated coil 1 is configured to be large in size and formed into a substrate, and the electric signal control unit is formed on the laminated coil substrate.

(Third embodiment)
FIG. 13 shows another example of the brushless motor according to the present invention.
This brushless motor includes a first rotor 101a in which a ring magnet 100 in which N poles and S poles in a large number of sets shown in FIG. 12 are alternately arranged is disposed on a yoke 105a serving as a support, and the ring magnet. An annular magnet 100b having a polarity opposite to that of 100a and disposed at the opposite position is coupled to a second rotor 101b disposed on a yoke 105b serving as a support, and coupled to the center of the first rotor 101a and the second rotor 101b. The rotary shaft 130, the first rotor 101a, the second rotor 101a, and a laminated coil that is provided through a predetermined gap and applies electromagnetic forces in opposite directions to the first and second rotors. 1, and an electric signal control unit that periodically supplies a drive current to the coil pole 50 formed in the laminated coil 1. The PCB on which a circuit pattern electrically connected to the input / output terminals is formed, and the first and second rotors 101a and 101b are fixed to the stator 125 via the bushing 140 so that the first and second rotors 101a and 101b rotate smoothly. A bearing 150 for supporting a rotating shaft connected to the first and second rotors is provided, and a three-drive power source is used. The laminated coil 1 used in the present embodiment is configured to be large in plan and formed into a substrate, and is integrally formed with a circuit pattern such as an electric signal control unit that periodically supplies drive current. . Since other configurations are substantially the same as those disclosed in the first embodiment, description thereof is omitted.

  This double rotor type brushless motor has a structure in which a stator in which a plurality of coil poles are formed is disposed substantially in the middle between the first and second rotors. The coil pole is set to attract or repel the annular magnets 100a and 100b of the first and second rotors, so that the first and second rotors are driven by a stator. The suction force or the repulsive force of the same magnitude in opposite directions is received, and vibration in the rotation axis direction is suppressed as compared with the single rotor type brushless motor. Also in this embodiment, since the gap between the first and second rotors 101a and 101b and the stator 125 is the same, the thickness of the stator 125 can be reduced, so that a thin motor with less vibration can be obtained. done.

  The laminated coil of the present invention is highly efficient, small and thin, and has high mass productivity. The brushless motor of the present invention using such a laminated coil is free from problems such as uneven rotation and torque ripple, and is thin and has little vibration.

It is a perspective view of the laminated coil which concerns on one Example of this invention. It is an exploded view which shows the internal structure of the laminated coil which concerns on one Example of this invention. It is an equivalent circuit of the laminated coil which concerns on one Example of this invention. (A) is the plane enlarged view of the some coil formed in the insulator layer of the laminated coil which concerns on one Example of this invention, (b) is the plane of the some coil formed in the other insulator layer. It is an enlarged view. (A) is an enlarged view of the 1st coil of the laminated coil which concerns on one Example of this invention, (b) is an enlarged view of the 2nd coil of the laminated coil which concerns on one Example of this invention. It is sectional drawing of the laminated coil which concerns on one Example of this invention. It is a plane enlarged view of the through-hole part of the laminated coil which concerns on one Example of this invention. 1 is an exploded perspective view showing an internal connection state of a laminated coil according to an embodiment of the present invention. It is a disassembled perspective view of the laminated substrate which shows an example of the manufacturing method of the laminated coil which concerns on this invention. 1 is a plan view of a multilayer substrate on which a plurality of multilayer coils according to the present invention are formed. It is sectional drawing of the brushless motor which concerns on one Example of this invention. It is a top view of the annular magnet used for the brushless motor concerning one example of the present invention. It is sectional drawing of the brushless motor which concerns on the other Example of this invention. It is the elements on larger scale of the conventional sheet-like coil. It is sectional drawing of the conventional sheet-like coil. It is sectional drawing of the brushless motor using the conventional sheet-like coil.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Laminated coil 10 Through-hole 60 1st coil pole 61 2nd coil pole 62 3rd coil pole 200, 201a, 201b, 201c, 210 1st connection line 251a-251h, 252a-252h, 253a-253h Coil 300a to 300c second coil

Claims (14)

A plurality of insulator layers and conductor patterns are laminated and pressure-bonded to form a laminate, and a plurality of coil poles made of coils formed by sintering the laminate are integrated (n is 2 or more). Natural number) laminated coil,
The laminated coil has an input terminal and an output terminal formed on the outer surface of the laminated body, a first connection line connecting the input terminal and the coil pole, and a second connection line connecting the in-phase coil poles in series. The first connection line and the second connection line are formed in a conductor pattern in a laminate, and the coil pole is sandwiched between the first connection line and the second connection line It formed in the layer,
A laminated coil , wherein coil patterns formed on adjacent insulator layers are laminated so as to reduce overlap .   The number of said coil poles is a multiple of n, and the number of coil poles for every phase is equal, The laminated coil of Claim 1 characterized by the above-mentioned.   The laminated coil according to claim 1 or 2, wherein n is 2 or 3.   The laminated coil according to any one of claims 1 to 3, wherein a substantially central portion of the laminated body has a through hole in which a rotating shaft and / or a bearing of a brushless motor is arranged. A plurality of insulator layers and conductor patterns are laminated and pressure-bonded to form a laminate, and a plurality of coil poles made of coils formed by sintering the laminate are integrated (n is 2 or more). Natural number) laminated coil,
The laminated coil has an input terminal and an output terminal formed on the outer surface of the laminated body, a first connection line connecting the input terminal and the coil pole, and a second connection line connecting the in-phase coil poles in series. The first connection line and the second connection line are formed in a conductor pattern in a laminate, and the coil pole is sandwiched between the first connection line and the second connection line Formed in layers
The first connection line includes an annular conductor portion surrounding a circular through-hole formed in a substantially central portion of the multilayer body, a first conductor portion that connects the annular conductor portion and the input terminal, A laminated coil comprising a second conductor portion extending from the annular conductor portion and connected to a coil pole.   The multilayer coil according to claim 1, wherein the input terminal, the output terminal, and the first connection line are formed on one main surface of the multilayer body.   The said 2nd connection line has two circular arc-shaped parts formed in the circumference from which a radius differs, and the radial part which connects these two circular arc-shaped parts, The any one of Claim 1 thru | or 6 characterized by the above-mentioned. The laminated coil of crab. A laminated coil for a three-phase motor in which a plurality of insulator layers and conductor patterns are laminated and pressure-bonded to form a laminated body, and coil poles composed of a plurality of coils formed by sintering the laminated body are integrated. ,
The laminated coil has an input terminal and an output terminal formed on the outer surface of the laminated body, a first connection line connecting the input terminal and the coil pole, and a second connection line connecting the in-phase coil poles in series. The first connection line and the second connection line are formed in a conductor pattern in a laminate, and the coil pole is sandwiched between the first connection line and the second connection line Formed in layers
The laminate is formed in a rectangular flat plate shape, and each of one input terminal and three output terminals is formed at different four corners of the same main surface of the laminate so that it can be directly mounted on a printed circuit board . A laminated coil characterized by   The coil pole is formed by connecting a plurality of coils formed in a plurality of insulator layers and overlapping in the stacking direction, at least a first coil wound clockwise from the inner peripheral side to the outer peripheral side, and an inner periphery from the outer peripheral side. A second coil wound clockwise to the side, the first coil and the second coil are connected by a through-hole formed in a laminate, and thus the first coil and the The laminated coil according to any one of claims 1 to 8, wherein the second coil has the same winding direction.   The laminated coil according to any one of claims 1 to 9, wherein coil poles of different phases are arranged at equiangular intervals around the motor rotation axis.   11. The laminated coil according to claim 10, wherein the in-phase coil poles are arranged at a rotationally symmetric position at 180 ° with respect to the rotation center of the motor rotation shaft.   The laminated coil according to any one of claims 1 to 11, wherein the coil is a fan-shaped spiral coil, and the opening angle is set to 55 ° or less about a rotation axis of a motor.   A brushless motor using the laminated coil according to any one of claims 1 to 12 as a stator, wherein the laminated coil is opposed to a rotor having permanent magnets adjacent to different magnetic poles via a magnetic gap. A brushless motor characterized by   The brushless motor according to claim 13, further comprising an electric signal control unit that periodically supplies a current to each coil pole of a different phase of the laminated coil.

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