WO2000049702A9 - A film coil and manufacturing method for motors and generators - Google Patents

A film coil and manufacturing method for motors and generators

Info

Publication number
WO2000049702A9
WO2000049702A9 PCT/KR2000/000127 KR0000127W WO0049702A9 WO 2000049702 A9 WO2000049702 A9 WO 2000049702A9 KR 0000127 W KR0000127 W KR 0000127W WO 0049702 A9 WO0049702 A9 WO 0049702A9
Authority
WO
WIPO (PCT)
Prior art keywords
coil
film
circuits
film coil
magnetic poles
Prior art date
Application number
PCT/KR2000/000127
Other languages
French (fr)
Korean (ko)
Other versions
WO2000049702A1 (en
Inventor
Hwan-Young Jae
Original Assignee
Embest Co Ltd
Pay Motor Ltd
Jae Hwan Young
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Embest Co Ltd, Pay Motor Ltd, Jae Hwan Young filed Critical Embest Co Ltd
Priority to JP2000600340A priority Critical patent/JP2003521861A/en
Priority to EP00905428A priority patent/EP1084530A1/en
Priority to AU26968/00A priority patent/AU2696800A/en
Publication of WO2000049702A1 publication Critical patent/WO2000049702A1/en
Publication of WO2000049702A9 publication Critical patent/WO2000049702A9/en

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/26—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors

Definitions

  • the present invention relates to a film coil having an improved coil pattern and a method for fabricating the film coil in a case of a motor and generator which use a film coil instead of conventional motor and generator which use a coil wound on a steel core.
  • a film coil of a motor and generator is formed by printing and plating a coil on an insulation film or etching a copper film attached on an insulation film.
  • a coil pattern for minimizing the connection points of the circuits between coil layers has a small coil density, so that it is difficult to obtain a film coil used for a motor and generator having enough torque and electromotive force.
  • the present invention relates to a film coil used for motors and generators and having an improved coil pattern and a method for fabricating the film coil.
  • a copper film attached on an insulation film is etched for thereby forming a lower coil layer, and an insulation film is printed on the coil layer except for the connection points, and a copper film formed by an electroless plating and an electroplating on the insulation film is etched for thereby forming an upper coil layer, so that a connection through the insulation film is automatically implemented
  • a film coil is generated with etching the two copper films attatched on both sides of insulation film and connecting the both side of coil pattern via the through holes.
  • a connection of the coil patterns on the both side of the insulation film is easily implemented, and it is possible to form a film coil for a motor and generator having a high coil density
  • Figure 1 is a concept view illustrating a cylindrical type film coil according to the present invention
  • Figure 2 is a concept view illustrating a circular type film coil according to the present invention
  • Figure 3 is a view illustrating a cylindrical type film coil having a plurality of rectangular closed circuits according to the present invention
  • Figure 4 is a view illustrating a cylindrical type film coil having a plurality of hexagonal closed circuits according to the present invention
  • Figure 5 is a view illustrating a circular type film coil having a plurality of rectangular closed circuits according to the present invention
  • Figure 6 is a view illustrating a circular type film coil having a plurality of hexagonal closed circuits according to the present invention
  • Figure 7 is a view illustrating a cylindrical type film coil having a rectangular closed circuit of a three-phase coil according to the present invention
  • Figure 8 is a view illustrating a cylindrical type film coil having a hexagonal closed circuit of a three-phase coil according to the present invention
  • Figure 9 is a concept view illustrating another embodiment of a circular type film coil of a three-phase coil according to the present invention.
  • Figure 10 is a construction view illustrating another embodiment of a circular type film coil of a three-phase coil according to the present invention.
  • Figure 11 is a view illustrating a cylindrical type film coil of a three-phase coil having a high coil density according to the present invention
  • Figure 12 is a view illustrating a circular type film coil of a three-phase coil having a high coil density according to the present invention
  • Figure 13 is a view illustrating another embodiment of a cylindrical type film coil having a plurality of hexagonal closed circuits according to the present invention.
  • Figure 14 is a view illustrating another embodiment of a circular type film coil having a plurality of hexagonal closed circuits according to the present invention
  • Figure 15 is a view illustrating another embodiment of a cylindrical type film coil of a three-phase coil having a high coil density according to the present invention
  • Figure 16 is a view illustrating another embodiment of a circular type film coil of a three-phase coil having a high coil density according to the present invention.
  • a cylindrical type film coil according to the present invention has a coil pattern in that a rectangular or hexagonal pattern is repeatedly formed.
  • the distance between the repeated rectangular or hexagonal patterns is the same as the distance of the magnetic poles.
  • the neighboring circuits are overlapped. Therefore, the circuits indicated by the solid line of Figure 1 are etched and formed of a copper film attached on the insulation film. Thereafter, an insulation film is printed on the coil layer except for the connection points. And, a copper film formed by an electroless plating and an electroplating is etched for thereby forming a circuit of a broken line of Figure 1.
  • the two copper films attached on both sides of an insulation film are etched with respect to the circuit of the solid and broken lines of Figure 1, and a through hole is drilled at a connection point of a circuit of both sides and is plated for thereby connecting the circuits of the both sides, so that a basic cylindrical type film coil according to the present invention is formed.
  • the pattern of a basic circular type film coil according to the present invention is a radial pattern changed from a rectangular pattern or a hexagonal pattern of a cylindrical type film coil.
  • a rectangular or hexagonal pattern which is similar to a shell pattern in the same number as that of the magnetic poles is formed on a circular pattern.
  • the period of the repeated rectangular or hexagonal patterns is the same as the period of the magnetic poles.
  • the circular type film coil is formed by etching a copper film attached on an insulation film corresponding to the solid line of Figure 2, and an insulation film is printed thereon except for the connection points, and then a copper film formed by an electroless plating and an electroplating is etched for thereby forming the circuits indicated by the broken line of Figure 2.
  • the two copper films attached on both sides of an insulation film are etched with respect to the circuit of the solid and broken lines of Figure 2, and a through hole is drilled at a connection point of a circuit of both sides and is plated for thereby connecting the circuits of the both sides.
  • the coil layers are stacked, and the start and end terminals of the rectangular or hexagonal pattern formed at each coil layer are connected by a conductive adhesive agent for thereby forming a circular type film coil.
  • the cylindrical type film coil having a plurality of closed circuits is formed by repeatedly forming the rectangular or hexagonal circuits formed of a plurality of closed circuits at a distance of the magnetic poles, and the neighboring rectangular or hexagonal circuits are in series connected each other.
  • the rectangular circuits are in series connected each other through one hole.
  • a plurality of the half hexagonal circuits is formed respectively, and a plurality of hexagonal circuits is formed by in series connecting through a hole drilled at a hexgonal apex, and a plurality of hexagonal circuits which are repeated at a distance of the magnetic poles is in series connected each other.
  • a plurality of rectangular closed circuits is alternately formed on the upper and lower coil layers with respect to the lengthy insulation film, and the closed circuits formed at the upper and lower coil layers are formed in a pair and are connected in series through a hole drilled at-the start terminal and end terminal of each closed circuit.
  • the rectangular coil formed of a plurality of closed circuits of Figure 3 has a low coil density but has a large connection terminal, so that it is easy to connect the same.
  • the number of connection is small. Therefore, it is generally used for a small precision motor or generator which requires a narrow line width of circuit.
  • a plurality of half hexagonal circuits is formed at the upper and lower coil layers with respect to a lengthy insulation film, and a plurality of hexagonal closed circuits is formed by connecting in series through a hole drilled at a hexagonal apex and is connected through a hole drilled at a start terminal and end terminal of each closed circuit which is repeated at a distance of the magnetic poles. Since the hexagonal circuits formed of a plurality of closed circuits of Figure 4 are in series connected through a hole drilled at the hexagonal apexe for forming one hexagonal closed circuit, the number of the connection is large. When forming the hexagonal film coil, since it is possible to form the film coil with a small space loss, it is possible to fabricate a film coil having a high coil density.
  • the rectangular or hexagonal film coils having a plurality of closed circuits are repeatedly formed at the copper film formed at the upper and lower layers about a lengthy insulation film at a distance of the magnetic poles, and the closed circuits formed at the upper and lower layers are in series connected for thereby forming in a cylindrical shape.
  • the cylindrical type film coil is formed so that the distance of the repeteated closed circuit of the rectangular or hexagonal coil is the same as the distance of the magnetic poles, whereby the same direction of force is applied to the closed circuit at the different magnetic pole.
  • the positions of the closed circuits of each coil layer are coincided, so that the same direction of force or electromotive force is generated at all coil layers at the differnent magnetic poles.
  • the distance of the closed circuit of each coil layer is adjusted based on the diameter of the coil layer.
  • the rectangular or hexagonal pattern of the cylindrical film coil is changed to a radial pattern.
  • the rectangular or hexagonal patterns formed of a plurality of closed circuits in a shell pattern are repeatedly formed at a period of the magnetic poles, and the ⁇ neighboring coil layers are in series connected and stacked.
  • a coil layer is formed by in series connecting a plurality of closed circuits formed at the upper and lower coil layers through one hole.
  • a plurality of half hexagonal circuits are formed at upper layer, and then a plurality of other half hexagonal circuits are formed at lower layer and then are connected in series through a hole drilled at a hexagonal apex for thereby forming a coil layer formed of a plurality of closed circuits.
  • the circular type film coil is formed by stacking the coil layers. The coil layers are in series connected based on the start and end terminals of a plurality of closed circuits of each coil layer.
  • a plurality of closed circuits formed on the upper and lower coil layers attached on the both side of a circular insulation film are in series connected through one hole, and the start and end terminals of the closed circuit of each coil layer are in series connected using a conductive adhesive agent.
  • the rectangular closed circuits positioned at the same position at each coil layer are in series connected and are stacked.
  • a hole is drilled at the terminal of the rectangular circuit of the first coil layer and the terminal of the rectangular circuit of the last coil layer, and the neighboring circuits are in series connected through the hole, so that a circular type film coil of a rectangular pattern having a plurality of closed circuits is fabricated.
  • the circular type film coil of the rectangular pattern having a plurality of closed circuits of Figure 5 have a low coil density, and the connection terminal is large, so that a connection is easily implemented.
  • the circular type film coil of the rectangular pattern is well adapted to a small precision motor or generator which requires a small number of connections and a narrow line width of the circuit.
  • a plurality of half hexagonal circuits are formed on the upper and lower coil layers attached on the both side of a circular insulation film and are connected through a hole drilled at a hexagonal apex for thereby forming a plurality of hexagonal closed circuit.
  • the start and end terminals of the closed circuit of each coil layer are in series connected between the coil layers using a conductive adhesive agent and are stacked.
  • the hexagonal closed circuits positioned at the same position at each coil layer are in series connected and are stcked.
  • a hole is drilled at the terminal of the hexagonal circuit of the first coil layer and the terminal of the hexagonal circuit of the last coil layer, and the neighboring hexagonal circuits are in series connected through the hole, so that a circular type film coil of a hexagonal pattern having a plurality of closed circuits is formed.
  • the hexagonal coil formed of a plurality of closed circuits of Figure 6 in order to form one hexagonal closed circuit, since the serial connection is implemented by a hole drilled at the hexagonal apexe, the number of the connection is large. However, when forming the hexagonal film coil, it is possible to form a film coil with a small space loss and a film coil having a high coil density.
  • the rectangular or hexagonal circuits of a plurality of closed circuits are formed by the number of the magnetic poles, and the start and end terminals of the closed circuit of each coil layer are in series connected using a conductive adhesive agent.
  • the rectangular or hexagonal closed circuits positioned at the same position at each coil layer are in series connected and are stacked.
  • the coils of the closed circuit formed by the number of the magnetic poles are connected in series.
  • a hole is drilled at the terminal of the rectangular or hexagonal circuit of the first coil layer and the terminal of the rectangular or hexagonal circuit of the last coil layer, and the neighboring rectangular or hexagonal circuits are connected in series through the hole for thereby fabricating a circular type film coil.
  • the period of the closed circuit of the rectangular or hexagonal circuits is the same as the period of the magnetic poles, and the circular type film coil is formed so that the same direction of force is applied to the closed circuit at the different magnetic poles.
  • the positions of the radial circuits of each coil layer are coincided. Therefore, at the different magnetic poles, the same direction of force or electromotive force is generated at all coil layers.
  • each phase is formed by forming the same film coil as the rectangular or hexagonal film coil of Figures 3 and 4 three times.
  • the closed circuits of each phase is deviated by 1/3 of the distance of the magnetic poles.
  • the coil layer of three phases is formed by forming the rectangular coil layer formed of a plurality of closed circuits of Figures 3 three times, and as shown in Figure 8, the coil layer of three phases is formed by forming the hexagonal coil layers formed of a plurality of closed circuits of Figure 4 three times.
  • the total line width of a plurality of the closed circuits of the rectangular or hexagonal circuit is smaller than 1/3 of the distance of the magnetic poles, so that the torque and. electromotive force are not canceled at the boundary of the magnetic poles.
  • a rectangular or hexagonal film coil having a plurality of closed circuits is repeatedly formed at the copper films formed on the both side of a lengthy insulation film at a distance of the magnetic poles.
  • the film coil formed by m series connecting the upper and lower closed circuits is repeatedly formed three times for thereby forming a three-phase film coil in a cylindrical shape.
  • the distance of the closed circuit of the rectangular or hexagonal coil is the same as the distance of the magnetic poles at each phase
  • the cylindrical type film coil of the three phases is formed so that the same direction of force is applied to the closed circuit at the different magnetic poles.
  • the positions of the closed circuit of the rectangular or hexagonal coil at each phase are deviated by 1/3 of the distance of the magnetic poles.
  • the terminals of the film coils of each phase are separately formed and are connected according to the Y- connection or ⁇ -connection
  • the same film coil as the rectangular or hexagonal film coil of Figures 5 and 6 is repeatedly stacked for thereby forming a film coil of each phase.
  • the positions of the closed circuit of each phase are deviated by 1/3 of the period of the magnetic poles.
  • the rectangular coil layer formed of a plurality of closed circuits of Figure 5 is repeatedly formed three times for thereby forming a film coil of the three phases
  • the hexagonal coil layer formed of a plurality of closed circuits of Figure 6 is repeatedly formed three times for thereby forming a film coil of the three phases.
  • the line width of a plurality of the closed circuits of the rectangular or hexagonal circuits is smaller than 1/3 of the period of the magnetic poles, and the torque and the electromotive force are not canceled at the boundary of the magnetic poles.
  • a rectangular or hexagonal coil of a plurality of closed circuits is formed at a layer by the number of magnetic poles, and the start and end terminals of the closed circuit of each coil layer are in series connected using a conductive adhesive agent.
  • the rectangular or hexagonal closed circuits positioned at the same position at each coil layer are in series connected and are stacked.
  • the coils of the closed circuit formed by the number of the magnetic poles are connected in series.
  • a hole is drilled at the terminal of the rectangular or hexagonal circuit of the first coil layer and the terminal of the rectangular or hexagonal circuit of the last coil layer, and the neighboring rectangular or hexagonal circuits are connected in series through the hole.
  • the stacked film coils are repeatedly stacked three times for thereby forming a circular type film coil of the three phases.
  • the period of the closed circuit of the rectangular or hexagonal coil is the same as the period of the magnetic poles at each phase.
  • the circular type film coil of the three phases is formed so that the same direction of force is applied to the closed circuit at the different magnetic poles.
  • the positions of the closed circuit of the rectangular or hexagonal coil at each phase are deviated by 1/3 of the period of the magnetic poles.
  • the terminals of the film coils of each phase are separately formed and are connected according to the Y- connection and ⁇ -connection.
  • the stacked film coils of each phase are repeatedly stacked three times, and the phases of the closed circuit of each phase are deviated by 1/3 of the period of the magnetic poles.
  • the phase difference of the closed circuit should be 90 degree.
  • the phase difference of the power source is 60 degree
  • the phase difference of the closed circuit is preferably larger than 60 degree. Therefore, as shown in Figure 9, three independent closed circuits corresponding to the three phases form one coil layer. If the two coil layers are stacked at odd angles from each other, it is possible to obtain the same effects as that three coil layers are stacked.
  • the phase difference of the closed circuit is larger than the phase difference of the power source.
  • Figure 10 The construction of Figure 10 is obtained by applying the circular type film coil having a plurality of closed circuits of Figure 9. Namely, a plurality of the rectangular closed circuits is formed by 3/4 number of the magnetic poles at the copper films formed on the both side of a circular insulation film. The upper and lower closed circuits are in series connected through one hole for thereby forming a first coil layer. A second coil layer has the same construction as the first coil layer except for that the closed circuit is at odd angles from the closed circuit of the first coil layer. A third coil layer is formed for in series connecting the opposite closed circuits of the first coil layer and the second coil layer.
  • the start and end terminals of the rectangular closed circuit at the same position are connected by a conductive adhesive agent.
  • a plurality of the first coil layers are stacked, and the coils formed of the rectangular closed circuit are connected with the coils which are at the same position.
  • a plurality of second coil layers are stacked, and the coils formed of the rectangular closed circuits are in series connected with the coils which are at the same position. Then, the closed circuits of the plurality of the first coil layer and the closed circuits of the plurality of the second coil layer which are opposite each other are connected in series with the third coil layer.
  • the coils are insulated, and a plurality of insulation layers are stacked for repeatedly and alternately connecting the start and end terminals of the closed circuit of the neighboring coil layers for thereby stacking a plurality of coil layers.
  • the radial circuits of each coil layer are overlapped at the same position
  • the terminal of each phase is connected with the start and end terminals of the closed circuit of the first and last layers for thereby forming a circular type film coil of the three phases.
  • the phase difference of the closed circuits should be obtained by dividing 360 degree by 3/2 number of the magnetic poles.
  • the hexagonal film coil does not repeatedly form the film coil of each phase by three times but forms one film coil, so that it is possible to form a film coil having a high coil density.
  • the closed circuits are connected through a hole drilled at the hexagonal apex, so that the number ol the connections is large.
  • the half hexagonal circuits are formed at the upper and lower coil layers about a lengthy insulation film as shown in Figure 11 by the number obtained by multiplying the number of windings and the triple of the number of the magnetic poles.
  • the connection is implemented through a hole drilled at a hexagonal apex, and the hexagonal closed circuits in the same phase and the same magnetic pole are connected in series.
  • the hexagonal closed circuits of the same phase are m series connected through a hole drilled at the start and end terminals of the hexagonal closed circuits in the same phase and the same magnetic pole.
  • a cylindrical type film coil of the three phases is formed connecting the start and end terminals of the continuous circuit of a phase according to the Y- connection or ⁇ -connection.
  • the half hexagonal circuits are formed at the upper and lower coil layers formed about the circular insulation film as shown in Figure 12 by the number obtained by multiplying the number of windings and the triple of the number of the magnetic poles.
  • the hexagonal closed circuits in the same phase and the same magnetic pole are in series connected through a hole drilled at a hexagonal apex, and the start and end terminals of the hexagonal closed circuits in the same phase and the same magnetic pole of a coil layer are formed.
  • the start and end terminals of the coil layers are connected in series each other using a conductive adhesive agent , and the coil layers are stacked.
  • the hexagonal closed circuits in the same phase and the same magnetic pole of the whole coil layer are connected in series after stacking operations.
  • a hole is drilled at the terminal of the hexagonal closed circuit of the first coil layer and the terminal of the hexagonal closed circuit of the last coil layer, and the hexagonal closed circuits of the same phase are in series connected through the hole.
  • a circular type film coil of the three phases is formed connecting the start and end terminals of the continuous circuit of a phase according to the Y-connection or ⁇ -connection.
  • the half hexagonal closed circuit are repeatedly formed at a distance of the magnetic poles at the upper and lower coil layers instead of forming the hexagonal film coil having a plurality of closed circuits and connecting in series through a hole drilled at a hexagonal apex, and the start and end terminals of the closed circuit in the same phase and the same magnetic pole.
  • the start and end terminals of the continuous circuit at both ends of the film coil are connected in series, it is possible to form an exploded hexagonal film coil.
  • the exploded hexagonal film coil when connecting in series the exploded hexagonal circuit of the upper and lower half exploded hexagonal circuit formed about a insulation film through a hole drilled at a hexagonal apex, one continuous circuit which is repeated at a distance of the magnetic poles is formed.
  • a plurality of continuous circuits is in series connected at the start and end terminals of each continuous circuit at both ends of the film coil.
  • half exploded hexagonal circuits are repeatedly formed at the upper and lower coil layers formed on the both side of a lengthy insulation film as shown in Figure 13 at a distance of the magnetic pole and the half exploded hexagonal circuits are in series connected through a hole formed at a hexagonal apex for thereby forming a plurality of continuous circuits.
  • a plurality of the continuous circuits are in series connected with the start and end terminals of the continuous circuit at the both ends of the continuous circuit for thereby forming a cylindrical type film coil.
  • the half exploded hexagonal circuits are formed at the upper and lower coil layers formed on the both side of a circular insulation film as shown in figure 14 at the period of the magnetic poles and are connected in series through a hole drilled at a hexagonal apex for thereby forming a plurality of continuous circuits.
  • the continuous circuits are connected in series with the start and end terminals of the continuous circuit for thereby forming a coil layer.
  • the start and end terminals of the serially connected continuous circuit at each coil layer are connected in series and stacked for thereby forming a circular type film coil.
  • the half exploded hexagonal circuits are formed at the upper and lower coil layers formed about a lengthy insulation film as shown in Figure 15.
  • the half exploded hexagonal circuits are formed by the number obtained by multiplying the number of windings and the triple of the number of the magnetic poles and are connected in series through a hole formed at a hexagonal apex for thereby forming a continuous circuit by the triple of the number of windings.
  • the continuous circuits of the same phase are connected in series with the start and end terminals at both ends of the continuous circuit for thereby forming the continuous circuit of a phase.
  • a cylindrical type film coil of the three phases is formed connecting the start and end terminals of the continuous circuit of a phase according to the Y-connection or ⁇ -connection.
  • the half exploded hexagonal circuits are formed at the upper and lower coil layers formed about a circular insulation film as shown in Figure 16,
  • the half exploded hexagonal circuts are formed by the number obtained by multiplying the number of windings and the triple of the number of the magnetic poles and are connected in series through a hole drilled at a hexagonal apex for thereby forming the continuous circuits by the triple of the number of windings.
  • the continuous circuits of the same phase are connected in series with the start and end terminals of the continuous circuit of a phase for thereby forming a coil layer.
  • start and end terminals of the serially connected continuous circuit at each coil layer are connected in series and stacked for thereby forming the continuous circuit of a phase.
  • a circular type film coil of the three phases is formed connecting the start and end terminals of the continuous circuit of a phase according to the Y-connection or ⁇ -connection.
  • the above-described film coil of the three phases may be adapted to the three phase power source and may be adapted to a power source of a certain phase by changing the number of the closed circuits in accordance with the number of the phase.
  • the copper film attached to a insulation film is etched for thereby forming a lower layer, and the copper film formed by an electroless plating and electroplating is etched except for the connection points for thereby forming an upper layer, so that the connection between the insulation film is automatically implemented.
  • the copper films attached at the both sides of an insulation film are etched for thereby forming a film coil, and the connections between the insulation film are implemented by plating through a hole drilled at the terminals of the both sides of the film coil for thereby implementing an easier connection between the copper film layers.
  • a hole is drilled at the terminals of the both side of the copper film attached on the insulation film.
  • the copper films are plated and etched thus to easily perform a plating process.
  • a connection of the upper and lower coil layers with respect to the insulation film is easily implemented for thereby forming a film coil with a small space loss, so that it is possible to form a motor and generator having a high coil density.
  • an etching method, a printing method, a plating method, etc. may be used for thereby fabricating automatically. Therefore, in the present invention, it is possible to fabricate a small precision motor and generator. A plurality of film coils is concurrently fabricated on a large film for thereby implementing a mass production, so that the fabrication cost is saved. Since the film coil according to the present invention has a small inductance and a high coil density, it is possible to fabricate a high efficient motor and generator.

Abstract

The present invention relates to a film coil having an improved coil pattern and a fabrication method thereof in the case of a motor and generator which uses a film coil instead of a conventional motor and generator in which a coil is wound on a steel core. In the preceding film coil of a motor and generator, a film coil is printed and plated on an insulation film, and a copper film attached to an insulation film is etched. In this case, it is difficult to stack many coil layers, and in addition, since a coil density is low, the preceding film coil is not widely used. In the present invention, a copper film attached on an insulation film is etched for thereby forming a lower coil, and an insulation film is printed on the coil except for the connection points, and a copper film formed by an electroless plating and electroplating is etched for thereby forming an upper coil, so that a connection between the insulation films is automatically implemented. In the present invention, a connection of the coils opposite with respect to the insulation film is easily implemented, and it is possible to form a film coil for a motor and generator having a high coil density by forming a film coil with a small space loss at one coil layer.

Description

A FILM COIL AND MANUFACTURING METHOD FOR MOTORS AND GENERATORS
TECHNICAL FIELD
The present invention relates to a film coil having an improved coil pattern and a method for fabricating the film coil in a case of a motor and generator which use a film coil instead of conventional motor and generator which use a coil wound on a steel core.
Background Art
A film coil of a motor and generator is formed by printing and plating a coil on an insulation film or etching a copper film attached on an insulation film. In the preceding coil pattern, it is difficult to stack many coil layers, and since coil density is small, the preceding film coil is not widely used.
In the conventional motor and generator, it is very difficult to wind coils on a stator or a rotor, so that the fabrication cost is high, and a compact size of motors and generators is hardly obtained. Therefore, a small precesion motor used for an audio equipment, a video equipment, a computer peripheral, an office automation system, etc. is hardly implemented with wire coils. Therefore, in order to overcome the problems, methods for printing and plating a coil of a motor and generator on an insulation film and for etching a copper film formed on an insulation film were introduced. When stacking a certain number of coil layers, since it is difficult to connect circuits of each coil layer, a film coil with a large number of coil layers is not easily obtained. In addition, a coil pattern for minimizing the connection points of the circuits between coil layers has a small coil density, so that it is difficult to obtain a film coil used for a motor and generator having enough torque and electromotive force. In addition, as the priority cases of the present invention, there are Korean Patent
Application Nos. 1998-7229, 1998-9933, and 1998-30302. For reference, the present invention relates to a film coil used for motors and generators and having an improved coil pattern and a method for fabricating the film coil.
DISCLOSURE OF THE INVENTION
Accordingly, it is an object of the present invention to provide a film coil of a motor and generator capable of obtaining a high coil density by fqrming a film coil with a small loss of a space in each coil layer.
It is another object of the present invention to provide a film coil having an improved coil pattern for a three phase Y-connected and Δ-connected motor or generator. In the present invention, a copper film attached on an insulation film is etched for thereby forming a lower coil layer, and an insulation film is printed on the coil layer except for the connection points, and a copper film formed by an electroless plating and an electroplating on the insulation film is etched for thereby forming an upper coil layer, so that a connection through the insulation film is automatically implemented Or, in the present invention, a film coil is generated with etching the two copper films attatched on both sides of insulation film and connecting the both side of coil pattern via the through holes. In the present invention, a connection of the coil patterns on the both side of the insulation film is easily implemented, and it is possible to form a film coil for a motor and generator having a high coil density
Additional advantages, objects and features of the invention will become more apparent from the following description
BRIEF DESCRIPTION OF DRAWINGS
The present invention will become more fully understood from the detailed description given herein below and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and where in
Figure 1 is a concept view illustrating a cylindrical type film coil according to the present invention,
Figure 2 is a concept view illustrating a circular type film coil according to the present invention,
Figure 3 is a view illustrating a cylindrical type film coil having a plurality of rectangular closed circuits according to the present invention,
Figure 4 is a view illustrating a cylindrical type film coil having a plurality of hexagonal closed circuits according to the present invention, Figure 5 is a view illustrating a circular type film coil having a plurality of rectangular closed circuits according to the present invention,
Figure 6 is a view illustrating a circular type film coil having a plurality of hexagonal closed circuits according to the present invention,
Figure 7 is a view illustrating a cylindrical type film coil having a rectangular closed circuit of a three-phase coil according to the present invention, Figure 8 is a view illustrating a cylindrical type film coil having a hexagonal closed circuit of a three-phase coil according to the present invention;
Figure 9 is a concept view illustrating another embodiment of a circular type film coil of a three-phase coil according to the present invention; Figure 10 is a construction view illustrating another embodiment of a circular type film coil of a three-phase coil according to the present invention;
Figure 11 is a view illustrating a cylindrical type film coil of a three-phase coil having a high coil density according to the present invention;
Figure 12 is a view illustrating a circular type film coil of a three-phase coil having a high coil density according to the present invention;
Figure 13 is a view illustrating another embodiment of a cylindrical type film coil having a plurality of hexagonal closed circuits according to the present invention;
Figure 14 is a view illustrating another embodiment of a circular type film coil having a plurality of hexagonal closed circuits according to the present invention; Figure 15 is a view illustrating another embodiment of a cylindrical type film coil of a three-phase coil having a high coil density according to the present invention;
Figure 16 is a view illustrating another embodiment of a circular type film coil of a three-phase coil having a high coil density according to the present invention.
BEST MODE FOR CARRYING OUT THE INVENTION
As shown in Figure 1 , a cylindrical type film coil according to the present invention has a coil pattern in that a rectangular or hexagonal pattern is repeatedly formed. The distance between the repeated rectangular or hexagonal patterns is the same as the distance of the magnetic poles. However, when forming the repeating rectangular or hexagonal coils are formed at one coil layer, the neighboring circuits are overlapped. Therefore, the circuits indicated by the solid line of Figure 1 are etched and formed of a copper film attached on the insulation film. Thereafter, an insulation film is printed on the coil layer except for the connection points. And, a copper film formed by an electroless plating and an electroplating is etched for thereby forming a circuit of a broken line of Figure 1. Or, the two copper films attached on both sides of an insulation film are etched with respect to the circuit of the solid and broken lines of Figure 1, and a through hole is drilled at a connection point of a circuit of both sides and is plated for thereby connecting the circuits of the both sides, so that a basic cylindrical type film coil according to the present invention is formed. As shown in Figure 2, the pattern of a basic circular type film coil according to the present invention is a radial pattern changed from a rectangular pattern or a hexagonal pattern of a cylindrical type film coil. A rectangular or hexagonal pattern which is similar to a shell pattern in the same number as that of the magnetic poles is formed on a circular pattern. The period of the repeated rectangular or hexagonal patterns is the same as the period of the magnetic poles. The circular type film coil is formed by etching a copper film attached on an insulation film corresponding to the solid line of Figure 2, and an insulation film is printed thereon except for the connection points, and then a copper film formed by an electroless plating and an electroplating is etched for thereby forming the circuits indicated by the broken line of Figure 2. Or, the two copper films attached on both sides of an insulation film are etched with respect to the circuit of the solid and broken lines of Figure 2, and a through hole is drilled at a connection point of a circuit of both sides and is plated for thereby connecting the circuits of the both sides. Thereafter, the coil layers are stacked, and the start and end terminals of the rectangular or hexagonal pattern formed at each coil layer are connected by a conductive adhesive agent for thereby forming a circular type film coil.
The cylindrical type film coil having a plurality of closed circuits is formed by repeatedly forming the rectangular or hexagonal circuits formed of a plurality of closed circuits at a distance of the magnetic poles, and the neighboring rectangular or hexagonal circuits are in series connected each other. In the upper and lower rectangular circuits as shown in Figure 3, the rectangular circuits are in series connected each other through one hole. In the upper and lower hexagonal circuits as shown in Figure 4, a plurality of the half hexagonal circuits is formed respectively, and a plurality of hexagonal circuits is formed by in series connecting through a hole drilled at a hexgonal apex, and a plurality of hexagonal circuits which are repeated at a distance of the magnetic poles is in series connected each other.
For the rectangular film coil as shown in Figure 3, a plurality of rectangular closed circuits is alternately formed on the upper and lower coil layers with respect to the lengthy insulation film, and the closed circuits formed at the upper and lower coil layers are formed in a pair and are connected in series through a hole drilled at-the start terminal and end terminal of each closed circuit. The rectangular coil formed of a plurality of closed circuits of Figure 3 has a low coil density but has a large connection terminal, so that it is easy to connect the same. In addition, the number of connection is small. Therefore, it is generally used for a small precision motor or generator which requires a narrow line width of circuit.
In addition, in the hexagonal film coil having a plurality of closed circuits, a plurality of half hexagonal circuits is formed at the upper and lower coil layers with respect to a lengthy insulation film, and a plurality of hexagonal closed circuits is formed by connecting in series through a hole drilled at a hexagonal apex and is connected through a hole drilled at a start terminal and end terminal of each closed circuit which is repeated at a distance of the magnetic poles. Since the hexagonal circuits formed of a plurality of closed circuits of Figure 4 are in series connected through a hole drilled at the hexagonal apexe for forming one hexagonal closed circuit, the number of the connection is large. When forming the hexagonal film coil, since it is possible to form the film coil with a small space loss, it is possible to fabricate a film coil having a high coil density.
Therefore, in the cylindrical type film coil, the rectangular or hexagonal film coils having a plurality of closed circuits are repeatedly formed at the copper film formed at the upper and lower layers about a lengthy insulation film at a distance of the magnetic poles, and the closed circuits formed at the upper and lower layers are in series connected for thereby forming in a cylindrical shape. The cylindrical type film coil is formed so that the distance of the repeteated closed circuit of the rectangular or hexagonal coil is the same as the distance of the magnetic poles, whereby the same direction of force is applied to the closed circuit at the different magnetic pole. When the lengthy film coil is wound in a cylindrical shape, the positions of the closed circuits of each coil layer are coincided, so that the same direction of force or electromotive force is generated at all coil layers at the differnent magnetic poles. The distance of the closed circuit of each coil layer is adjusted based on the diameter of the coil layer.
In the circular type film coil having a plurality of closed circuits, the rectangular or hexagonal pattern of the cylindrical film coil is changed to a radial pattern. The rectangular or hexagonal patterns formed of a plurality of closed circuits in a shell pattern are repeatedly formed at a period of the magnetic poles, and the ■neighboring coil layers are in series connected and stacked. In the rectangular film coil of Figure 5, a coil layer is formed by in series connecting a plurality of closed circuits formed at the upper and lower coil layers through one hole. In a hexagonal film coil of Figure 6, a plurality of half hexagonal circuits are formed at upper layer, and then a plurality of other half hexagonal circuits are formed at lower layer and then are connected in series through a hole drilled at a hexagonal apex for thereby forming a coil layer formed of a plurality of closed circuits. The circular type film coil is formed by stacking the coil layers. The coil layers are in series connected based on the start and end terminals of a plurality of closed circuits of each coil layer.
As shown in Figure 5, in the circular type film coil of the rectangular pattern having a plurality of closed circuits, a plurality of closed circuits formed on the upper and lower coil layers attached on the both side of a circular insulation film are in series connected through one hole, and the start and end terminals of the closed circuit of each coil layer are in series connected using a conductive adhesive agent. The rectangular closed circuits positioned at the same position at each coil layer are in series connected and are stacked. A hole is drilled at the terminal of the rectangular circuit of the first coil layer and the terminal of the rectangular circuit of the last coil layer, and the neighboring circuits are in series connected through the hole, so that a circular type film coil of a rectangular pattern having a plurality of closed circuits is fabricated.The circular type film coil of the rectangular pattern having a plurality of closed circuits of Figure 5 have a low coil density, and the connection terminal is large, so that a connection is easily implemented. In addition, therefore, the circular type film coil of the rectangular pattern is well adapted to a small precision motor or generator which requires a small number of connections and a narrow line width of the circuit.
As shown in Figure 6, in the circular type film coil of the hexagonal pattern having a plurality of closed circuits, a plurality of half hexagonal circuits are formed on the upper and lower coil layers attached on the both side of a circular insulation film and are connected through a hole drilled at a hexagonal apex for thereby forming a plurality of hexagonal closed circuit. The start and end terminals of the closed circuit of each coil layer are in series connected between the coil layers using a conductive adhesive agent and are stacked. The hexagonal closed circuits positioned at the same position at each coil layer are in series connected and are stcked. A hole is drilled at the terminal of the hexagonal circuit of the first coil layer and the terminal of the hexagonal circuit of the last coil layer, and the neighboring hexagonal circuits are in series connected through the hole, so that a circular type film coil of a hexagonal pattern having a plurality of closed circuits is formed. In the hexagonal coil formed of a plurality of closed circuits of Figure 6, in order to form one hexagonal closed circuit, since the serial connection is implemented by a hole drilled at the hexagonal apexe, the number of the connection is large. However, when forming the hexagonal film coil, it is possible to form a film coil with a small space loss and a film coil having a high coil density.
In the circular type film coil having a plurality of closed circuits, the rectangular or hexagonal circuits of a plurality of closed circuits are formed by the number of the magnetic poles, and the start and end terminals of the closed circuit of each coil layer are in series connected using a conductive adhesive agent. The rectangular or hexagonal closed circuits positioned at the same position at each coil layer are in series connected and are stacked. When the stacking operation is completed, the coils of the closed circuit formed by the number of the magnetic poles are connected in series. A hole is drilled at the terminal of the rectangular or hexagonal circuit of the first coil layer and the terminal of the rectangular or hexagonal circuit of the last coil layer, and the neighboring rectangular or hexagonal circuits are connected in series through the hole for thereby fabricating a circular type film coil. The period of the closed circuit of the rectangular or hexagonal circuits is the same as the period of the magnetic poles, and the circular type film coil is formed so that the same direction of force is applied to the closed circuit at the different magnetic poles. The positions of the radial circuits of each coil layer are coincided. Therefore, at the different magnetic poles, the same direction of force or electromotive force is generated at all coil layers.
In the cylindrical type film coil of the three phases, each phase is formed by forming the same film coil as the rectangular or hexagonal film coil of Figures 3 and 4 three times. When the cylindrical type film coil of three phases is formed, the closed circuits of each phase is deviated by 1/3 of the distance of the magnetic poles. As shown in figure 7, the coil layer of three phases is formed by forming the rectangular coil layer formed of a plurality of closed circuits of Figures 3 three times, and as shown in Figure 8, the coil layer of three phases is formed by forming the hexagonal coil layers formed of a plurality of closed circuits of Figure 4 three times. At this time, the total line width of a plurality of the closed circuits of the rectangular or hexagonal circuit is smaller than 1/3 of the distance of the magnetic poles, so that the torque and. electromotive force are not canceled at the boundary of the magnetic poles.
In the cylindrical type film coil of the three phases, a rectangular or hexagonal film coil having a plurality of closed circuits is repeatedly formed at the copper films formed on the both side of a lengthy insulation film at a distance of the magnetic poles. The film coil formed by m series connecting the upper and lower closed circuits is repeatedly formed three times for thereby forming a three-phase film coil in a cylindrical shape. The distance of the closed circuit of the rectangular or hexagonal coil is the same as the distance of the magnetic poles at each phase The cylindrical type film coil of the three phases is formed so that the same direction of force is applied to the closed circuit at the different magnetic poles. The positions of the closed circuit of the rectangular or hexagonal coil at each phase are deviated by 1/3 of the distance of the magnetic poles. The terminals of the film coils of each phase are separately formed and are connected according to the Y- connection or Δ-connection
In the circular type film coil of the three phases, the same film coil as the rectangular or hexagonal film coil of Figures 5 and 6 is repeatedly stacked for thereby forming a film coil of each phase. In the circular type film coil, the positions of the closed circuit of each phase are deviated by 1/3 of the period of the magnetic poles. In the circular type film coil of the three phases of the rectangular pattern, the rectangular coil layer formed of a plurality of closed circuits of Figure 5 is repeatedly formed three times for thereby forming a film coil of the three phases, and in the circular type film coil of the three phases of the hexagonal pattern, the hexagonal coil layer formed of a plurality of closed circuits of Figure 6 is repeatedly formed three times for thereby forming a film coil of the three phases. At this time, the line width of a plurality of the closed circuits of the rectangular or hexagonal circuits is smaller than 1/3 of the period of the magnetic poles, and the torque and the electromotive force are not canceled at the boundary of the magnetic poles.
In the circular type film coil of the three phases, a rectangular or hexagonal coil of a plurality of closed circuits is formed at a layer by the number of magnetic poles, and the start and end terminals of the closed circuit of each coil layer are in series connected using a conductive adhesive agent. The rectangular or hexagonal closed circuits positioned at the same position at each coil layer are in series connected and are stacked. After completing the stacking operation, the coils of the closed circuit formed by the number of the magnetic poles are connected in series. A hole is drilled at the terminal of the rectangular or hexagonal circuit of the first coil layer and the terminal of the rectangular or hexagonal circuit of the last coil layer, and the neighboring rectangular or hexagonal circuits are connected in series through the hole. The stacked film coils are repeatedly stacked three times for thereby forming a circular type film coil of the three phases. The period of the closed circuit of the rectangular or hexagonal coil is the same as the period of the magnetic poles at each phase. The circular type film coil of the three phases is formed so that the same direction of force is applied to the closed circuit at the different magnetic poles. The positions of the closed circuit of the rectangular or hexagonal coil at each phase are deviated by 1/3 of the period of the magnetic poles. The terminals of the film coils of each phase are separately formed and are connected according to the Y- connection and Δ-connection.
In the circular type film coil of the three phases, the stacked film coils of each phase are repeatedly stacked three times, and the phases of the closed circuit of each phase are deviated by 1/3 of the period of the magnetic poles. However, when forming the circuit of the film coil of Figure 9, it is possible to form a circular type film coil of the three phases based on less stacks. If the number of the magnetic poles is 4, the phase difference of the closed circuit should be 90 degree. However, the phase difference of the power source is 60 degree, the phase difference of the closed circuit is preferably larger than 60 degree. Therefore, as shown in Figure 9, three independent closed circuits corresponding to the three phases form one coil layer. If the two coil layers are stacked at odd angles from each other, it is possible to obtain the same effects as that three coil layers are stacked. Here, the phase difference of the closed circuit is larger than the phase difference of the power source.
The construction of Figure 10 is obtained by applying the circular type film coil having a plurality of closed circuits of Figure 9. Namely, a plurality of the rectangular closed circuits is formed by 3/4 number of the magnetic poles at the copper films formed on the both side of a circular insulation film. The upper and lower closed circuits are in series connected through one hole for thereby forming a first coil layer. A second coil layer has the same construction as the first coil layer except for that the closed circuit is at odd angles from the closed circuit of the first coil layer. A third coil layer is formed for in series connecting the opposite closed circuits of the first coil layer and the second coil layer.
In order to connect the neighboring coil layers, the start and end terminals of the rectangular closed circuit at the same position are connected by a conductive adhesive agent. A plurality of the first coil layers are stacked, and the coils formed of the rectangular closed circuit are connected with the coils which are at the same position. A plurality of second coil layers are stacked, and the coils formed of the rectangular closed circuits are in series connected with the coils which are at the same position. Then, the closed circuits of the plurality of the first coil layer and the closed circuits of the plurality of the second coil layer which are opposite each other are connected in series with the third coil layer. The coils are insulated, and a plurality of insulation layers are stacked for repeatedly and alternately connecting the start and end terminals of the closed circuit of the neighboring coil layers for thereby stacking a plurality of coil layers. The radial circuits of each coil layer are overlapped at the same position The terminal of each phase is connected with the start and end terminals of the closed circuit of the first and last layers for thereby forming a circular type film coil of the three phases. In a plurality of the rectangular closed circuits, the phase difference of the closed circuits should be obtained by dividing 360 degree by 3/2 number of the magnetic poles.
In the cylindrical and circular type film coils of the three phases, the hexagonal film coil does not repeatedly form the film coil of each phase by three times but forms one film coil, so that it is possible to form a film coil having a high coil density. In order to form one hexagonal closed circuit, in the hexagonal coil formed of a plurality of closed circuits, the closed circuits are connected through a hole drilled at the hexagonal apex, so that the number ol the connections is large. However, when forming the film coil of the three phases, it is possible to form a film coil with a small space loss, so that it is possible to fabricate a film coil having a high coil density
Namely, in the cylindrical type film coil of the three phases of the hexagonal pattern, the half hexagonal circuits are formed at the upper and lower coil layers about a lengthy insulation film as shown in Figure 11 by the number obtained by multiplying the number of windings and the triple of the number of the magnetic poles. The connection is implemented through a hole drilled at a hexagonal apex, and the hexagonal closed circuits in the same phase and the same magnetic pole are connected in series. Then, the hexagonal closed circuits of the same phase are m series connected through a hole drilled at the start and end terminals of the hexagonal closed circuits in the same phase and the same magnetic pole. A cylindrical type film coil of the three phases is formed connecting the start and end terminals of the continuous circuit of a phase according to the Y- connection or Δ-connection.
In the circular type film coil of the three phases of the hexagonal pattern, the half hexagonal circuits are formed at the upper and lower coil layers formed about the circular insulation film as shown in Figure 12 by the number obtained by multiplying the number of windings and the triple of the number of the magnetic poles. The hexagonal closed circuits in the same phase and the same magnetic pole are in series connected through a hole drilled at a hexagonal apex, and the start and end terminals of the hexagonal closed circuits in the same phase and the same magnetic pole of a coil layer are formed. And, the start and end terminals of the coil layers are connected in series each other using a conductive adhesive agent , and the coil layers are stacked. Then, the hexagonal closed circuits in the same phase and the same magnetic pole of the whole coil layer are connected in series after stacking operations. A hole is drilled at the terminal of the hexagonal closed circuit of the first coil layer and the terminal of the hexagonal closed circuit of the last coil layer, and the hexagonal closed circuits of the same phase are in series connected through the hole. A circular type film coil of the three phases is formed connecting the start and end terminals of the continuous circuit of a phase according to the Y-connection or Δ-connection.
The half hexagonal closed circuit are repeatedly formed at a distance of the magnetic poles at the upper and lower coil layers instead of forming the hexagonal film coil having a plurality of closed circuits and connecting in series through a hole drilled at a hexagonal apex, and the start and end terminals of the closed circuit in the same phase and the same magnetic pole. When the start and end terminals of the continuous circuit at both ends of the film coil are connected in series, it is possible to form an exploded hexagonal film coil.
In the exploded hexagonal film coil, when connecting in series the exploded hexagonal circuit of the upper and lower half exploded hexagonal circuit formed about a insulation film through a hole drilled at a hexagonal apex, one continuous circuit which is repeated at a distance of the magnetic poles is formed. A plurality of continuous circuits is in series connected at the start and end terminals of each continuous circuit at both ends of the film coil.
In the cylindrical type film coil of the exploded hexagonal pattern, half exploded hexagonal circuits are repeatedly formed at the upper and lower coil layers formed on the both side of a lengthy insulation film as shown in Figure 13 at a distance of the magnetic pole and the half exploded hexagonal circuits are in series connected through a hole formed at a hexagonal apex for thereby forming a plurality of continuous circuits. A plurality of the continuous circuits are in series connected with the start and end terminals of the continuous circuit at the both ends of the continuous circuit for thereby forming a cylindrical type film coil.
In the circular type film coil using an exploded hexagonal pattern, the half exploded hexagonal circuits are formed at the upper and lower coil layers formed on the both side of a circular insulation film as shown in figure 14 at the period of the magnetic poles and are connected in series through a hole drilled at a hexagonal apex for thereby forming a plurality of continuous circuits. The continuous circuits are connected in series with the start and end terminals of the continuous circuit for thereby forming a coil layer. In addition, the start and end terminals of the serially connected continuous circuit at each coil layer are connected in series and stacked for thereby forming a circular type film coil.
In the cylindrical type film coil of the three phases using an exploded hexagonal pattern, the half exploded hexagonal circuits are formed at the upper and lower coil layers formed about a lengthy insulation film as shown in Figure 15. The half exploded hexagonal circuits are formed by the number obtained by multiplying the number of windings and the triple of the number of the magnetic poles and are connected in series through a hole formed at a hexagonal apex for thereby forming a continuous circuit by the triple of the number of windings. The continuous circuits of the same phase are connected in series with the start and end terminals at both ends of the continuous circuit for thereby forming the continuous circuit of a phase. A cylindrical type film coil of the three phases is formed connecting the start and end terminals of the continuous circuit of a phase according to the Y-connection or Δ-connection.
In the circular type film coil of the three phases using an exploded hexagonal pattern, the half exploded hexagonal circuits are formed at the upper and lower coil layers formed about a circular insulation film as shown in Figure 16, The half exploded hexagonal circuts are formed by the number obtained by multiplying the number of windings and the triple of the number of the magnetic poles and are connected in series through a hole drilled at a hexagonal apex for thereby forming the continuous circuits by the triple of the number of windings. The continuous circuits of the same phase are connected in series with the start and end terminals of the continuous circuit of a phase for thereby forming a coil layer. In addition, the start and end terminals of the serially connected continuous circuit at each coil layer are connected in series and stacked for thereby forming the continuous circuit of a phase. A circular type film coil of the three phases is formed connecting the start and end terminals of the continuous circuit of a phase according to the Y-connection or Δ-connection.
In addition, the above-described film coil of the three phases may be adapted to the three phase power source and may be adapted to a power source of a certain phase by changing the number of the closed circuits in accordance with the number of the phase.
In the present invention, the copper film attached to a insulation film is etched for thereby forming a lower layer, and the copper film formed by an electroless plating and electroplating is etched except for the connection points for thereby forming an upper layer, so that the connection between the insulation film is automatically implemented. In addition, the copper films attached at the both sides of an insulation film are etched for thereby forming a film coil, and the connections between the insulation film are implemented by plating through a hole drilled at the terminals of the both sides of the film coil for thereby implementing an easier connection between the copper film layers. In the present invention, a hole is drilled at the terminals of the both side of the copper film attached on the insulation film. Then, the copper films are plated and etched thus to easily perform a plating process. In addition, in the present invention, a connection of the upper and lower coil layers with respect to the insulation film is easily implemented for thereby forming a film coil with a small space loss, so that it is possible to form a motor and generator having a high coil density.
In order to fabricate the film coil according to the present invention, an etching method, a printing method, a plating method, etc. may be used for thereby fabricating automatically. Therefore, in the present invention, it is possible to fabricate a small precision motor and generator. A plurality of film coils is concurrently fabricated on a large film for thereby implementing a mass production, so that the fabrication cost is saved. Since the film coil according to the present invention has a small inductance and a high coil density, it is possible to fabricate a high efficient motor and generator. Although the preferred embodiment of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as recited in the accompanying claims.

Claims

What is claimed is:
1. A cylindrical type film coil which is characterized in that a plurality of rectangular closed circuits are alternately formed at the both coil surfaces formed about a lengthy insulation film at the distance of the magnetic poles, and the closed circuit formed at upper and lower coil layers are formed in pair and are connected in series with a start and end terminals of each closed circuit through a hole, and a cylindrical type coil is implemented by winding a film coil formed at the upper and lower layers attached on the both side of the insulation film in a cylindrical shape.
2. A cylindrical type film coil which is characterized in that a plurality of half hexagonal half circuits are formed at the both coil surfaces formed about a lengthy insulation film and are connected in series through a hole drilled at a hexagonal apex for thereby forming a plurality of hexagonal closed circuits at the distance of the magnetic poles, and the hexagonal closed circuits are connected in series through a hole drilled at a start and end terminals of the hexagonal closed circuit, and a cylindrical type coil is implemented by winding a film coil at the upper and lower layers attatched on the both side of the insulation film in a cylindrical shape.
3. A cylindrical type film coil which is characterized in that a plurality of half exploded hexagonal circuits are continuously formed at the both coil surfaces formed about a lengthy insulation film at the distance of the magnetic poles and are connected in series through a hole drilleded at a hexagonal apex for thereby forming a plurality of continuous circuits, and the continuous circuits are connected in series at the start and end terminals of the continuous circuit at the both ends of the film coil, and a cylindrical type coil is implemented by winding a film coil formed at the upper and lower layers attatched on the both side of the insulation film in a cylindrical shape.
4. The film coil of claim 1, wherein when the film coil is wound in a cylindrical shape, the distance of the closed circuit in the direction of the circumference is the same as the distance of the magnetic poles, and the closed circuits in the direction of the circumference are overlapped at the same position in each film coil layer for thereby forming a lengthy cylindrical circuit.
5. The film coil of claim 2, wherein when the film coil is wound in a cylindrical shape, the distance of the closed circuit in the direction of the circumference is the same as the distance of the magnetic poles, and the closed circuits in the direction of the circumference are overlapped at the same position in each film coil layer for thereby forming a lengthy cylindrical circuit.
6. The film coil of claim 3, wherein when the film coil is wound in a cylindrical shape, the distance of the closed circuit in the direction of the circumference is the same as the distance of the magnetic poles, and the closed circuits in the direction of the circumference are overlapped at the same position in each film coil layer for thereby forming a lengthy cylindrical circuit.
7. A cylindrical type film coil of the three phases which is characterized in that a three-phase film coil is formed by forming a film coil of claim 1 three times, and when forming the same in a cylindrical shape, the phase of the closed circuits in the direction of the circumference at the film coil of each phase is deviated by 1/3 of the distance of the magnetic poles.
8. A cylindrical type film coil of the three phases which is characterized in that a three-phase film coil is formed by forming a film coil of claim 2 three times, and when forming the same in a cylindrical shape, the phase of the closed circuits in the direction of the circumference at the film coil of each phase is deviated by 1/3 of the distance of the magnetic poles.
9. A cylindrical type film coil of the three phases which is characterized in that a three-phase film coil is formed by forming a film coil of claim 3 three times, and when forming the same in a cylindrical shape, the phase of the closed circuit in the direction of the circumference at the film coil of each phase is deviated by 1/3 of the distance of the magnetic poles.
10. The film coil of claim 7, wherein the line width of a plurality of closed circuits in the direction of the circumference is smaller than 1/3 of the distance of the magnetic poles.
11. The film coil of claim 8, wherein the line width of a plurality of closed circuits in the direction of the circumference is smaller than 1/3 of the distance of the magnetic poles.
12. The film coil of claim 9, wherein the line width of a plurality of closed circuits in the direction of the circumference is smaller than 1/3 of the distance of the magnetic poles.
13. A circular type film coil which is characterized in that a plurality of rectangular closed circuits at the both coil surfaces formed about a circular insulation film is formed by the number of the magnetic poles, and a plurality of insulation layers are stacked for alternately connecting in series a start and end terminals of a closed circuit at a coil layer by connecting in series the upper and lower closed circuits through one hole and insulating the coil layers between the coil layers, and the radial circuitss of each coil layer are stacked to be overlapped at the same position, and the independent closed circuits are connected in series by forming a hole at a start and end terminal of the first and last layers.
14. A circular type film coil which is characterized in that a plurality of half hexagonal circuits is formed at the both coil surfaces formed about a circular insulation film and is connected in series through a hole drilled at a hexagonal apex, and a plurality of insulation layers are stacked alternately connecting in series a start and end terminals of the closed circuit formed at the neighboring coil layer by insulating the coil layers between the coil layer formed of a plurality of hexagonal closed circuits by the number of the magnetic poles, and the coil layers are formed so that a radial circuit of each coil layer is overlapped at the same position, and the independent closed circuits are connected in series by forming a hole at the start and end terminals of the closed circuit of the first and lasr layers.
15. A circular type film coil which is characterized in that a plurality of half exploded hexagonal circuits is formed at the both coil surfaces formed about a circular insulation film at a period of the magnetic poles and is connected in series through a hole drilled at a hexagonal apex for thereby forming a plurality of continuous circuits which are repeatedly formed at a distance of the magnetic poles, and a coil layer is formed by connecting in series the start and end terminals of the continuous circuit, and the start and end terminals of the serially connected continuous circuit at each coil layer are connected in series with the coil layer.
16. The film coil of claim 13, wherein when stacking a plurality of coil layers, the radial circuits of reach coil layer are overlapped at the same position, and the period of the radial circuit is the same as the period of the magnetic poles.
17. The film coil of claim 14, wherein when stacking a plurality of coil layers, the radial circuits of reach coil layer are overlapped at the same position, and the period of the radial circuit is the same as the period of the magnetic poles.
18. The film coil of claim 15, wherein when stacking a plurality of coil layers, the radial circuits of reach coil layer are overlapped at the same position, and the period of the radial circuit is the same as the period of the magnetic poles.
19. A circular type film coil of the three phases which is characterized in that a three-phase film coil is formed by forming a film coil of claim 13 three times, and when continuously stacking the same, the phase of a radial circuit at the film coil of each phase of the three-phase film coil is deviated by 1/3 of the period of the magnetic poles.
20. A circular type film coil of the three phases which is characterized in that a three-phase film coil is formed by forming a film coil of claim 14 three times, and when continuously stacking the same, the phase of a radial circuit at the film coil of each phase of the three-phase film coil is deviated by 1/3 of the period of the magnetic poles.
21. A circular type film coil of the three phases which is characterized in that a three-phase film coil is formed by forming a film coil of claim 15 three times, and when continuously stacking the same, the phase of a radial circuit at the film coil of each phase of the three-phase film coil is deviated by 1/3 of the period of the magnetic poles.
22. The film coil of claim 19, wherein the line width of a plurality of radial circuits are smaller than 1/3 of the period of the magnetic poles.
23. The film coil of claim 20, wherein the line width of a plurality of radial circuits are smaller than 1/3 of the period of the magnetic poles.
24. The film coil of claim 21, wherein the line width of a plurality of radial circuits are smaller than 1/3 of the period of the magnetic poles
25 A circular type film coil of the three phases comprising a first coil layer in which a plurality of rectangular closed circuits at the both coil surfaces formed about a circular insulation film, is formed by the 3/4 number of the number of the magnetic poles and is connected in series through a hole, a second coil layer, which has the same pattern as the first coil layer, in which the rectangular closed circuits are at odd angles from the rectangular closed circuits of the first coil layer, and a third coil layer for connecting in series the opposite closed circuits of the first coil layer and the second coil layer, wherein a plurality of the first coil layers are stacked, and the rectangular closed circuits are connected in series with the rectangular closed circuits which are at the same position, and a plurality of the second coil layers are stacked, and the rectangular closed circuits are connected in series with the rectangular closed circuits which are at the same position, and the plurality of the closed circuits of the first coil layer and the plurality of the closed circuit of the second coil layer which are opposite each other are connected in series with the third coil layer, and a plurality of insulation layers are stacked for alternately connecting in series the start and end terminals of the closed circuit at the neighboring coil layer, and the radial circuits of each coil layer are overlapped at the same position, and the terminal of each phase is extended to the start and end terminals of the closed circuit of the first and last coil layers
26 The film coil of claim 25, wherein in a plurality of the rectangular closed circuits, the period of the inner most circuit is larger than the value obtained by dividing
360 degree by 3/2 of the number of the magnetic poles
27 A cylindrical type film coil of the three phases which is characterized in that a half hexagonal circuit is formed at the both coil surfaces formed about a lengthy insulation film and the hexagonal closed circuits are formed by the number obtained by multiplying the number of windings and the triple of the number of the magnetic poles by connecting in series through a hole formed at a hexagonal apex, and the hexagonal closed circuits of each phase which are repeated at a distance of the magnetic poles are connected in series
28. A cylindrical type film coil of the three phases which is characterized in that a half exploded hexagonal circuit is formed at the both coil surfaces formed about a lengthy insulation film by the multiple number obtained by multiplying the number of windings and the triple of the number of the magnetic poles, and continuous circuits are formed by the triple of the number of windings connecting in series through a hole drilled at a hexagonal apex, and the continuous circuits of each phase are connected in series with the start and end terminals at the both ends of the continuous circuit.
29. The film coil of claim 27, wherein when the film coil is wound in a cylindrical shape, the distance of the closed circuit in the direction of the circumference is the same as the distance of the magnetic poles, and the closed circuit is formed so that the closed circuits are overlapped at the same position in each film coil layer.
30. The film coil of claim 28, wherein when the film coil is wound in a cylindrical shape, the distance of the closed circuit in the direction of the circumference is the same as the distance of the magnetic poles, and the closed circuit is formed so that the closed circuits are overlapped at the same position in each film coil layer.
31. A circular type film coil of the three phases, comprising: a coil layer in which half hexagonal circuits are formed at the both coil surfaces formed about a circular insulation film by the multiple number obtained by multiplying the number of windings and the triple of the number of the magnetic poles and are connected in series through a hole drilled at a hexagonal apex, and a start and end terminal of the closed circuits in the same phase and magnetic pole is formed by the triple of the number of the magnetic poles; and a plurality of insulation layers for alternately and serially connecting the start and end terminals of the closed circuit in the same phase and magnetic pole at the neighboring coil layer by insulating the coil layers, wherein the radial circuits of each coil layer are overlapped at the same position for thereby forming a coil layer, and the closed circuits of the same phase are connected in series by forming a hole at the start end terminals of the closed circuits of each phase of the first and last surfaces.
32. A circular type film coil of the three phases which is characterized in that a half exploded hexagonal circuit is formed at the both coil surfaces formed about a circular insulation film by the multiple number obtained by multiplying the number of windings and the triple of the number of the magnetic poles, and are connected in series through a hole drilled at a hexagonal apex, and the start and end terminals of the closed circuits in the same phase and magnetic pole are connected in series for thereby forming one coil layer having three phases, and the start and end terminals of the continuous circuit of each phase at the coil layer are connected in series with the coil layers.
33. The film coil of claim 31, wherein when stacking a plurality of coil layers, the radial circuits of each coil layer are stacked at the same position, and the period in which the radial circuit of each phase is repeated is the same as the period of the magnetic poles for thereby forming a radial circuit.
34. The film coil of claim 32, wherein when stacking a plurality of coil layers, the radial circuits of each coil layer are stacked at the same position, and the period in which the radial circuit of each phase is repeated is the same as the period of the magnetic poles for thereby forming a radial circuit.
35. The film coil of one of claims 7, 8, 9, 19, 20, 21, 27, 28, 31, and 32, wherein said film coil is adapted to a three-phase power source, and is adapted to a different phase of the power source by changing the number of the closed circuits in accordance with the number of the phases.
36. A film coil fabricating method which is characterized in that, for a connection of the both coil surfaces formed about an insulation film, a lower coil layer is formed at an insulation film by etching a copper film attached on the insulation film, and an insulation film is printed on the coil layer except for the connection points, and an upper coil layer is formed by etching a copper film formed by an electroless plating and electroplating for thereby implementing a connection between the insulation films, and a film coil is formed by etching the two copper films attached on the both side of an insulation film, and connecting the both sides of circuits by plating a hole at a terminal opposite with respect to the insulation film.
PCT/KR2000/000127 1999-02-20 2000-02-17 A film coil and manufacturing method for motors and generators WO2000049702A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
JP2000600340A JP2003521861A (en) 1999-02-20 2000-02-17 Membrane coils for motors and generators
EP00905428A EP1084530A1 (en) 1999-02-20 2000-02-17 A film coil and manufacturing method for motors and generators
AU26968/00A AU2696800A (en) 1999-02-20 2000-02-17 A film coil and manufacturing method for motors and generators

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
KR1999/5715 1999-02-20
KR1019990005715A KR100311900B1 (en) 1999-02-20 1999-02-20 A Thin Film Coil for Motors or Generators

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KR20030089546A (en) * 2002-05-16 2003-11-22 주식회사 메타시스템 BLDC motor having flexible stator
KR100780915B1 (en) * 2006-08-10 2007-11-30 한국표준과학연구원 Method of manufacturing rotating coil of angular vibration exciter which uses the multi layer pcb manufacturing method
JP4571685B2 (en) * 2008-12-12 2010-10-27 本田技研工業株式会社 Stator coil of axial gap type rotating electrical machine
US8319595B2 (en) 2010-01-13 2012-11-27 Cosmo Mechanics Co., Ltd. Coil apparatus
JP4996712B2 (en) * 2010-04-26 2012-08-08 本田技研工業株式会社 Stator coil of axial gap type rotating electrical machine
CN102148561A (en) * 2011-03-08 2011-08-10 上海交通大学 Self-holding type implantable miniature generator using vasomotion
KR101245176B1 (en) 2012-10-19 2013-03-25 송병로 Moter by using coil winding of etching foil type

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US4271370A (en) * 1979-09-21 1981-06-02 Litton Systems, Inc. Double air gap printed circuit rotor
JP2628872B2 (en) * 1987-12-22 1997-07-09 旭化成工業株式会社 Coil for flat brushless motor
JPH0213249A (en) * 1988-06-28 1990-01-17 Murata Mfg Co Ltd Manufacture of miniture motor coil
JPH02269450A (en) * 1990-02-21 1990-11-02 Hitachi Ltd Stator coil
JP3536375B2 (en) * 1994-09-08 2004-06-07 株式会社安川電機 Sheet coil type resolver

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KR20000056416A (en) 2000-09-15
WO2000049702A1 (en) 2000-08-24
CN1294772A (en) 2001-05-09
KR100311900B1 (en) 2001-11-02
JP2003521861A (en) 2003-07-15
TW471210B (en) 2002-01-01
AU2696800A (en) 2000-09-04

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