CN115864760B

CN115864760B - Coil device, axial flux motor and manufacturing method of coil device

Info

Publication number: CN115864760B
Application number: CN202310070904.0A
Authority: CN
Inventors: 方文; 杨帆; 林阳; 姜学广
Original assignee: Changzhou Shuanglian Magnetoelectric Technology Co ltd
Current assignee: Changzhou Shuanglian Magnetoelectric Technology Co ltd
Priority date: 2023-02-07
Filing date: 2023-02-07
Publication date: 2023-05-05
Anticipated expiration: 2043-02-07
Also published as: CN115864760A

Abstract

The invention relates to the technical field of solar cell processing equipment, in particular to a coil device, an axial flux motor and a manufacturing method of the coil device, comprising two copper layers and a process layer, wherein the two copper layers are respectively positioned above and below the process layer, and a first axis is perpendicular to the process layer; copper bars on the same copper layer are arranged along the second axis direction, copper bars on an upper copper layer are respectively U1, U2 and U3. U n-1 along the second axis direction, copper bars on a lower copper layer are respectively D1, D2 and D3 Dn along the second axis direction, and the copper bars are sequentially connected end to end through connecting columns according to the sequence of D1, U1, D2, U2, D3 and U3. Dn.

Description

Coil device, axial flux motor and manufacturing method of coil device

Technical Field

The invention relates to the technical field of solar cell processing equipment, in particular to a coil device, an axial flux motor and a manufacturing method of the coil device.

Background

In the current background of the demand for new energy, the application of high-performance motors is greatly increased, and the ultra-miniature motors can be applied to miniature electronic devices, even MEMS devices. High performance electric machines can be divided into two categories, axial flux machines (axial flux machines) and radial flux machines (radial flux motor). Axial flux machines are difficult to miniaturize due to their operating mechanism, resulting in relatively large volumes.

Disclosure of Invention

The purpose of the invention is that: overcomes the defects in the prior art and provides a coil device, an axial flux motor and a manufacturing method of the coil device.

In order to solve the technical problems, the invention adopts the following technical scheme:

in a first aspect, the present application provides a coil device comprising two copper layers and a process layer, wherein the two copper layers comprise an upper copper layer and a lower copper layer, the two layers are respectively located above and below the process layer, and a first axis is perpendicular to the process layer;

copper strips on the same copper layer are arranged along a second axis direction, copper strips on an upper copper layer are respectively U1, U2 and U3...Un-1 along the second axis direction, copper strips on a lower copper layer are respectively D1, D2 and D3..Dn along the second axis direction, and a plurality of copper strips are sequentially connected through connecting columns head and tail according to the sequence of D1, U1, D2, U2, D3 and U3...Un-1 and Dn, wherein n is a positive integer.

Further, copper bars on the same copper layer are arranged equidistantly.

Further, the copper bars on the same copper layer are coplanar.

Further, the lower copper layer further comprises a first lead-out copper bar and a second lead-out copper bar, the first lead-out copper bar is connected with the head end of the D1, and the second lead-out copper bar is connected with the tail end of the Dn.

Further, the process layer comprises a PI layer and a magnetic layer, the magnetic layer comprises a magnetic sheet and thermosetting adhesive, and the thermosetting adhesive is distributed around the magnetic sheet.

In a second aspect, the present application also provides a flux machine comprising a coil device of an axial flux machine as defined in any one of the preceding claims.

Further, the motor comprises a stator, a disc rotor and a main shaft, wherein the stator comprises a stator seat and at least six coils, the coil devices are inserted in the stator seat, at least six coil devices are rotationally symmetrical around the main shaft, the second shaft is parallel to the main shaft, the disc rotor is connected to the main shaft, the main shaft penetrates through the stator, and the disc rotor and the stator are coaxial with the main shaft.

Furthermore, positive m-shaped through holes are formed in the stator base, the value of m is consistent with the number of the coil devices, clamping grooves are formed in the hole walls of the positive m-shaped through holes, and the coil devices are clamped in the clamping grooves.

Furthermore, the two ends of the regular m-shaped through hole are respectively connected with an end cover, the end covers are detachably connected with the stator base, and the main shaft is connected with the end covers through bearings.

In a third aspect, the present application also includes a method of manufacturing a coil device for an axial-flux electric machine, comprising the steps of:

coating liquid PI on the surface of the copper foil to form a PI copper-clad plate;

etching copper strips on the lower copper layer on the copper foil surface of the PI copper-clad plate;

printing a photoresist layer with a groove in the middle on a PI surface of a PI copper-clad plate as a die of the magnetic sheet;

carrying out chemical deposition of a magnetic material on the upper surface of the photoresist, namely the upper surface of the PI layer at the groove;

dissolving and removing the photoresist and the magnetic material on the photoresist, wherein the rest magnetic material becomes a magnetic sheet;

coating thermosetting adhesive around the magnetic sheet;

hot-pressing copper foil on the upper surface of the thermosetting adhesive and the magnetic sheet to form an upper copper layer;

etching copper strips on the upper copper layer;

drilling holes at two ends of the copper bar, and electroplating the through holes to form connecting columns in the through holes.

The technical scheme of the invention has the beneficial effects that:

1. certain embodiments of the present application provide for a multiple reduction in the volume of an axial motor stator by designing the miniature motor coils in the cross-section of the PCB substrate, enabling the implementation of an axial ultra miniature motor.

2. The width of the copper wire of the flat coil, namely the copper bar in the application, is controllable, and the skin effect is reduced conveniently.

3. The flattened copper strip design can increase the thermal contact interface and can better dissipate heat.

4. The integrated design of magnetic material and coil can improve the inductance of planar coil to promote the efficiency of motor.

5. Since the present application is a flattened design, there is no significant requirement for the thickness of PI and thus can be manufactured using liquid PI. The traditional method that liquid PI is directly coated on the copper foil instead of PI-glue-copper foil can realize roll-to-roll production, reduces or basically eliminates the connection time between two PI composite copper foil coiled materials, and can improve the production efficiency compared with the conventional production mode of one-piece production.

Drawings

In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings that are needed in the description of the embodiments will be briefly described below, it being obvious that the drawings in the following description are only some embodiments of the present invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art. Wherein the method comprises the steps of

FIG. 1 is an oblique view of a coil device of the present application;

FIG. 2 is a schematic structural diagram of a first step in the method for manufacturing a coil device according to the present application;

FIG. 3 is a schematic structural diagram of a second step in the method for manufacturing a coil device according to the present application;

fig. 4 is a schematic structural diagram of a third step in the method for manufacturing a coil device according to the present application;

FIG. 5 is a schematic structural diagram of a fourth step in the method for manufacturing a coil device according to the present application;

FIG. 6 is a cross-sectional view of step four in the method of manufacturing a coil device of the present application;

fig. 7 is a schematic structural diagram of a fifth step in the method for manufacturing a coil device according to the present application;

FIG. 8 is a cross-sectional view of step five in the method of manufacturing a coil device of the present application;

fig. 9 is a schematic structural diagram of step six and step seven in the method for manufacturing a coil device according to the present application;

FIG. 10 is a cross-sectional view of step six and step seven in the method of manufacturing a coil device of the present application;

FIG. 11 is a schematic structural diagram of step eight in the method for manufacturing a coil device according to the present application;

FIG. 12 is a schematic structural view of step nine of the method for fabricating a coil device according to the present application, and is also an oblique view of another angle of the coil device according to the present application;

FIG. 13 is a cross-sectional view of step nine in the method of manufacturing a coil device of the present application;

FIG. 14 is a schematic structural view of an axial flux electric machine of the present application;

FIG. 15 is a front view of an axial flux electric machine of the present application;

FIG. 16 is a cross-sectional view taken at B-B of FIG. 15;

FIG. 17 is a side view of a axial-flux electric machine of the present application;

FIG. 18 is a cross-sectional view taken at A-A of FIG. 17;

FIG. 19 is a cross-sectional view taken at C-C of FIG. 17;

fig. 20 is an exploded view of an axial flux electric machine of the present application.

1. A coil device; 11. a copper layer is arranged on the substrate; 12. a PI layer; 13. a photoresist; 14. a magnetic material; 15. a thermosetting adhesive; 16. a lower copper layer; 17. a connecting column; 21. a stator base; 22. a junction box; 23. a box cover; 3. a disc rotor; 4. an end cap; 5. a bearing; 6. clamping springs; 7. a main shaft.

Detailed Description

The invention will now be described in further detail with reference to the accompanying drawings. The drawings are simplified schematic representations which merely illustrate the basic structure of the invention and therefore show only the structures which are relevant to the invention. The present invention will be described in detail by means of a schematic structural diagram, etc., which is only an example, and should not limit the scope of the present invention. In addition, the three-dimensional space of length, width and depth should be included in actual fabrication.

Referring to fig. 1-20, the present application provides a coil device 1 of an axial flux electric machine, specifically, the coil device 1 is mainly used for an electric machine, and the coil device 1 is used for an electric machine as an example for the following detailed description.

Referring to fig. 1, a coil device 1 includes two copper layers and a process layer, wherein the two copper layers are respectively located above and below the process layer, a first axis is perpendicular to the process layer, and the first axis is the Z axis in fig. 1 and 12;

referring to fig. 1 and 12, copper strips on the same copper layer are arranged along a second axis direction, copper strips on an upper copper layer 11 are U1, U2, U3., un-1, and copper strips on a lower copper layer 16 are D1, D2, D3, dn, respectively, and the copper strips are sequentially connected end to end through a connecting column 17 in the order of D1, U1, D2, U2, D3, U3., un-1, dn, and the second axis is the Y axis in fig. 1 and 12, wherein n is a positive integer.

In some embodiments of the present application, the design of the miniature motor coil is performed on the cross section of the PCB substrate, so that the volume of the stator of the axial motor is reduced by multiple, especially, the thickness between the spindle 7 and the motor housing can be reduced to be small, i.e. the outer diameter of the motor can be made small, so that the realization of the axial miniature motor is possible.

Referring to fig. 1 and 12, copper bars on the same copper layer are arranged equidistantly. The mode that the equidistance was arranged can place more copper bars in shorter length, and copper bars on upper copper layer and the lower copper layer can increase more coil number of turns in shorter length.

Referring to fig. 1 and 12, several copper strips on the same copper layer are coplanar. The coil that coplane copper bar constitutes can guarantee that the coil is long and narrow more for this application realizes flattening more easily.

Referring to fig. 12 and 13, the lower copper layer 16 further includes a first lead copper bar connected to the head end of D1 and a second lead copper bar connected to the tail end of Dn. The first lead-out copper bar and the second lead-out copper bar can facilitate wiring of the application, and welding spots are provided for the embodiment of the application.

Referring to fig. 12 and 13, the process layer includes a PI layer 12 and a magnetic layer, the magnetic layer includes a magnetic sheet and a thermosetting adhesive 15, and the thermosetting adhesive 15 is distributed around the magnetic sheet.

Referring to fig. 14-20, the present application also provides a flux machine comprising a coil device 1 of an axial flux machine as described in any one of the preceding claims.

Since the flux motor in the present embodiment includes the coil device 1 described above, the largest feature of the coil device 1 in the above embodiment is flattening, and thus the flux motor in the present embodiment can achieve the features of good heat dissipation and small outer diameter, and is particularly suitable for being mounted in an elongated device to achieve miniaturization and high integration of the apparatus.

Referring to fig. 14-20, the stator comprises a stator seat 21 and at least six coil devices 1, the coil devices 1 are inserted in the stator seat 21, at least six coil devices 1 are rotationally symmetrical around the main shaft 7, the second shaft is parallel to the main shaft 7, the disc rotor 3 is connected to the main shaft 7, the main shaft 7 passes through the stator, and the disc rotor 3 and the stator are coaxial with the main shaft 7.

Referring to fig. 14-20, a positive m-shaped through hole is formed in the stator seat 21, the value of m is identical to the number of the coil devices 1, a clamping groove is formed on the wall of the positive m-shaped through hole, and the coil devices 1 are clamped in the clamping groove to fix the coil devices 1.

The wiring hole is opened on the lateral wall of stator seat, and the wiring hole is connected with terminal box 22, and terminal box 22 upper cover is equipped with lid 23, and the wiring hole is convenient to be connected inside cable and outside cable, and terminal box 22 regularly provides the space for the arrangement of cable, simultaneously, terminal box 22 and lid 23 can also provide the guard action to the cable.

Referring to fig. 13-20, two ends of the regular m-shaped through hole are respectively connected with an end cover 4, the end covers 4 are detachably connected with the stator seat 21, the main shaft 7 is connected with the end covers 4 through a bearing 5, a rotor is sleeved on the main shaft 7, and the rotor and the main shaft 7 are kept relatively static.

Specifically, be provided with the installation pipe of placing bearing 5 on the end cover 4, the jump ring groove has been seted up to the installation intraductal to place jump ring 6 and carry out the axial spacing to bearing 5.

More specifically, the number of the snap spring grooves is two, and snap springs 6 are arranged on two sides of the bearing 5 to realize axial limiting of the bearing 5.

And in addition, a stop block is arranged in the mounting pipe so as to limit the axial direction of one side of the bearing 5, and the other side is limited by using a clamp spring 6.

More specifically, the dog sets up in the inboard, and the outside axial of bearing 5 uses jump ring 6 to carry out spacingly, and the benefit of setting like this is easy to assemble, only needs a slice jump ring 6 of installation when the installation, and convenient maintenance simultaneously, jump ring 6 are in the outside, and the dog is inside structure makes and need not to open end cover 4 just can carry out the change of bearing 5.

Referring to fig. 2-13, the present application further includes a method for manufacturing a coil device 1 of an axial flux electric machine, comprising the steps of:

step one: referring to fig. 2, a PI copper clad laminate is formed by coating liquid PI onto a surface of a copper foil;

since the present application is a flattened design, there is no significant requirement for the thickness of PI and thus can be manufactured using liquid PI. The liquid PI is directly coated on the copper foil, and a transmission method of PI-glue-copper foil is not used, so that roll-to-roll production can be realized, the connection time between two PI composite copper foil coiled materials is reduced or basically eliminated, and compared with a conventional production mode of one-piece production, the production efficiency can be improved.

Step two: referring to fig. 3, copper bars on the lower copper layer 16 are etched on the copper foil surface of the PI copper clad laminate;

step three: referring to fig. 4, a photoresist 13 layer with a groove in the middle is printed on the PI surface of the PI copper-clad plate to serve as a mold of the magnetic sheet;

the binding force between the magnetic material 14 and PI is poor, and the stability of the structure can be improved by adding the photoresist 13 layer.

Step four: referring to fig. 5 and 6, the upper surface of the photoresist 13, i.e. the upper surface of the PI layer 12 at the groove, is subjected to chemical deposition of a magnetic material 14;

step five: referring to fig. 7 and 8, the photoresist 13 and the magnetic material 14 thereon are dissolved and removed, and the remaining magnetic material 14 becomes a magnetic sheet;

step six: referring to fig. 9 and 10, a thermosetting adhesive 15 is coated around the magnetic sheet;

the thermosetting adhesive 15 is a duplex modified epoxy thermosetting adhesive film, and the copper foil is a single-sided red copper foil, so that the bonding force between the two is further increased.

Step seven: referring to fig. 9 and 10, a lower copper layer 16 is formed by hot-pressing copper foil on the upper surfaces of the thermosetting resin 15 and the magnetic sheet;

step eight: referring to fig. 11, copper bars on the upper copper layer 11 are etched on the upper copper layer 11;

step nine: referring to fig. 12 and 13, holes are drilled at both ends of the copper bar, and the through holes are plated so that connection posts 17 are formed in the through holes.

The connecting column 17 can connect two layers of copper bars so that two layers of copper bars enclose the city coil, and automatic operation is easier to realize in direct drilling electroplating compared with a drilling plug wire welding mode, so that the production efficiency of the coil can be further improved, and the quality of the coil is ensured.

The following two embodiments are classified according to the manufacturing method of the lead-out copper bar:

example 1

Step ten is added after the above steps.

Step ten: and respectively welding the first lead-out copper bar and the lead-out copper bar on the head end of the D1 and the tail end of the DN.

Example two

Modifying the first step and the second step, and adding one step in the second step and the third step.

Increasing the width when the PI copper-clad plate is manufactured in the first step so that the width of the PI copper-clad plate is larger than the sum of the lengths of the copper bars and the lead-out copper bars I or II;

modifying the second step as follows: etching copper strips on the lower copper layer 16, the first lead-out copper strips and the second lead-out copper strips on the copper foil surface of the PI copper-clad plate;

a step is added between the second step and the third step: excess PI is milled or cut away so that lead-out copper bar one and lead-out copper bar two protrude out of PI layer 12.

With the above-described preferred embodiments according to the present invention as an illustration, the above-described descriptions can be used by persons skilled in the relevant art to make various changes and modifications without departing from the scope of the technical idea of the present invention. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention. The technical scope of the present invention is not limited to the description, but must be determined according to the scope of claims.

Claims

1. A method for manufacturing a coil device, characterized by:

the method comprises the following steps:

coating thermosetting adhesive around the magnetic sheet;

etching copper strips on the upper copper layer;

drilling holes at two ends of the copper bar, electroplating the through holes to form connecting columns in the through holes,

the coil device manufactured by the manufacturing method comprises two copper layers and a process layer, wherein the two copper layers comprise an upper copper layer and a lower copper layer, the two layers are respectively positioned above and below the process layer, and a first axis is perpendicular to the process layer;

copper strips on the same copper layer are arranged along a second axis direction, copper strips on an upper copper layer are respectively U1, U2 and U3...Un-1 along the second axis direction, a plurality of copper strips on a lower copper layer are respectively D1, D2 and D3..Dn along the second axis direction, and a plurality of copper strips are sequentially connected through connecting columns head and tail according to the sequence of D1, U1, D2, U2, D3 and U3...Un-1 and Dn, wherein n is a positive integer.

2. A coil device characterized in that: the method of claim 1, wherein the copper strips are equidistantly arranged on the same copper layer.

3. A coil device characterized in that: the method of claim 1, wherein the copper strips are coplanar.

4. A coil device characterized in that: the manufacturing method of claim 1, wherein the lower copper layer further comprises a first lead-out copper bar and a second lead-out copper bar, the first lead-out copper bar is connected with the head end of the D1, and the second lead-out copper bar is connected with the tail end of the Dn.

5. A coil device characterized in that: the manufacturing method of claim 1, wherein the process layer comprises a PI layer and a magnetic layer, the magnetic layer comprises a magnetic sheet and thermosetting glue, and the thermosetting glue is distributed around the magnetic sheet.

6. An axial flux electric machine, characterized by: the axial flux electric machine comprising a coil device as claimed in any one of claims 2 to 5.

7. The axial flux electric machine of claim 6, wherein: the stator comprises a stator seat and at least six coils, the coil devices are inserted in the stator seat, at least six coil devices are rotationally symmetrical around the main shaft, the second shaft is parallel to the main shaft, the disc rotor is connected to the main shaft, the main shaft penetrates through the stator, and the disc rotor and the stator are coaxial with the main shaft.

8. The axial flux electric machine of claim 7, wherein: the stator seat is internally provided with positive m-shaped through holes, the value of m is consistent with the number of the coil devices, clamping grooves are formed in the hole walls of the positive m-shaped through holes, and the coil devices are clamped in the clamping grooves.

9. The axial flux electric machine of claim 8, wherein: the two ends of the regular m-shaped through hole are respectively connected with an end cover, the end covers are detachably connected with the stator base, and the main shaft is connected with the end covers through bearings.