KR20210031688A - Systems and devices for axial field rotational energy devices - Google Patents

Abstract

The axial field rotational energy device may comprise a housing having an axis. The stator assembly is mounted on the housing and has an axially stacked stator panel and a separate panel. Each stator panel includes a respective printed circuit board (PCB) with respective coils that are electrically conductive and interconnected within each PCB. Further, the rotor assembly including the rotor is rotatably mounted in a housing at an axial end opposite to the stator assembly. The rotors can be mechanically joined together. Each rotor may contain a magnet with leading and trailing edges. The trailing edge of one magnet and the leading edge of adjacent magnets may be parallel to each other to define a consistent circumferential spacing about the axis between adjacent magnets.

Description

Systems and devices for axial field rotational energy devices

FIELD OF THE INVENTION The present invention relates generally to axial field rotational energy devices, and more particularly to systems, methods and apparatus for modular motors and generators having one or more printed circuit board (PCB) stators.

A conventional axial air gap brushless motor with a layered disk stator is known, such as US 5789841. This patent discloses a stator winding using wires interconnected in a wave or wrap configuration. Such motors are relatively large and difficult to manufacture. An axial electric device using a PCB stator is also known, such as US 6411002, US 7109625 and US 8823241. However, some of these designs are complex, relatively expensive, and not modular. Therefore, the improvement of cost-effective axial field rotational energy devices continues to be of interest.

Embodiments of a system, method and apparatus for an axial field rotational energy device are disclosed. For example, an axial field rotational energy device may comprise a housing having an axis with an axial direction. The stator assembly may be mounted on the housing and includes a plurality of stator panels stacked in an axial direction and a panel separated from each other. Each stator panel includes a printed circuit board (PCB) having a plurality of coils each electrically conductive and interconnected within each PCB. Each PCB may be configured such that a current flowing through any one of each of the plurality of coils likewise flows through all of each of the plurality of coils, so that each stator panel consists of a single electric phase. Further, a rotor assembly including a plurality of rotors may be rotatably mounted in the housing at opposite axial ends of the stator assembly. Each rotor can be mechanically joined together. Each rotor may contain a magnet with leading and trailing edges. The rear edge of one magnet and the front edge of adjacent magnets may be parallel to each other to define a consistent circumferential spacing about the axis between adjacent magnets.

The foregoing and other objects and advantages of these embodiments will be apparent to those skilled in the art in view of the following detailed description taken in conjunction with the appended claims and the accompanying drawings.

In a manner in which features and advantages of the embodiments can be achieved and understood in more detail, a more detailed description may be given with reference to the embodiments shown in the accompanying drawings. However, the drawings illustrate only some embodiments and thus there may be other equally effective embodiments and should not be regarded as limiting the scope.
1 is a plan view of an embodiment of an axial field rotational energy device.
FIG. 2 is a cross-sectional side view of the device of FIG. 1 taken along line 2-2 of FIG. 1;
3 is an exploded isometric view of an embodiment of the device of FIGS. 1 and 2;
4 is a plan view of an embodiment of a single-phase stator having a printed circuit board (PCB).
5 is an enlarged isometric view of an embodiment of only the coil layer of the stator.
6A is an enlarged, exploded, isometric view of another embodiment of only the coil layer of the stator.
6B is an enlarged isometric view of a part of the stator shown in FIG. 5.
6C is an enlarged, exploded isometric view of a part of the stator shown in FIG. 5.
6D is an enlarged isometric view of a part of the stator shown in FIG. 5.
7 is a schematic partially exploded side view of an embodiment of a layered trace of a stator.
8 is a plan view of an embodiment of a multiphase stator with a PCB.
9 is a plan view of an alternative embodiment of vertically adjacent rotor magnets and an upper coil layer of a stator.
10 is a simplified top view of an embodiment of another embodiment of an axial field rotational energy device.
11 is a simplified cross-sectional side view of the device of FIG. 10;
12 is a simplified, exploded isometric view of an embodiment of the apparatus of FIGS. 10 and 11;
13 is a simplified plan view of an embodiment of a segmented stator.
14 is a simplified plan view of another embodiment of a segmented stator.
15 is a simplified plan view of an embodiment of a trace for a PCB.
16 is a simplified isometric view of the embodiment of FIG. 15;
17 is a schematic, exploded isometric view of an embodiment of a trace layer of the PCB of FIGS. 15 and 16;
18 is a plan view of an embodiment of a module.
19 is a side cross-sectional view of the module of FIG. 18, along line 19-19 of FIG. 18;
20A is an exploded isometric view of an embodiment of the module of FIGS. 18 and 19.
20B-20H are isometric and cross-sectional views of an embodiment of the module of FIG. 20A.
21 is an exploded isometric view of another embodiment of a module.
Figure 22 is an assembled isometric view of the embodiment of the module of Figure 21;
23 and 24 are isometric views of an embodiment of a stacked module in which the latches are open and closed, respectively.
25 is an interior plan view of a module embodiment.
26 is an exploded isometric view of an embodiment of a module body.
27 is a plan view of an embodiment of a PCB stator for an axial field rotation device.
28 is an enlarged plan view of a portion of the embodiment of the PCB stator of FIG. 27;
29 is an isometric view of an embodiment of a stator including an attached sensor.
30 is an isometric view of an embodiment of a stator including an embedded sensor.
31 is an isometric view of an embodiment of an assembly for a stator segment.
32 is a perspective isometric view of an embodiment of an assembly for a stator segment.
33 is an exploded isometric view of another embodiment of the device.
Fig. 34 is an axial cross-sectional view of the device of Fig. 33;
35 is a plan view of another embodiment of a stator panel.
36 is a top exploded view of another embodiment of a stator panel.
37 is an enlarged partial plan view of another embodiment of a stator panel.
38 is an enlarged partial plan view of another embodiment of a stator panel.
39 is a cross-sectional side view of another embodiment of an axial field rotational energy device.
Fig. 40 is a front view of the device of Fig. 39;
FIG. 41 is a front view of the device of FIG. 39 along lines 41-41, with a portion of the housing and the stator assembly removed.
42 is a half cross-sectional side view of an embodiment of a rotor assembly.
43 is an isometric view of the rotor assembly of FIG. 42;
FIG. 44 is a front view of the device of FIG. 39 along lines 44-44 with a portion of the housing and a portion of the rotor assembly removed.
Figure 45 is an isometric view of the device of Figure 44;
46 is an isometric view of an embodiment of a rotor hub.
The use of the same reference symbols in different drawings indicates similar or identical items.

1 to 3 show various views of an embodiment of a device 31 comprising an axial field rotary energy device (AFRED). Depending on the application, the device 31 may comprise a motor that converts electrical energy into mechanical power, or a motor that converts mechanical power into electrical energy.

I. Panels

An embodiment of the device 31 may comprise at least one rotor 33 comprising a rotating shaft 35 and a magnet (ie, at least one magnet 37). The plurality of magnets 37 are shown in FIG. Each magnet 37 may include at least one magnetic pole, and the magnet 37 may have various shapes such as trapezoidal shape, conical shape, and the like.

The device 31 may also comprise a stator 41 that is coaxial with the rotor 33. The rotor 33 may be coupled to the shaft 43, and one of a mount plate, a fastener, a washer, a bearing, a spacer, or an alignment element. It can be combined with other hardware such as one or more. An embodiment of the stator 41 may include a single unitary panel, such as the printed circuit board (PCB) 45 shown in FIG. 5. The PCB 45 may include at least one PCB layer 47. For example, a particular embodiment described herein may include 12 PPCB layers 47. The PCB layers 47 may be axially parallel and spaced apart. Each PCB layer 47 may include at least one conductive trace 49. Each trace 49 is a separate conductive feature formed on a given PCB layer 47. For example, eight traces 49 are shown in FIG. 4. The trace 49 may be configured in a desired pattern such as the coil shown in FIG. 4.

4 shows an embodiment of one PCB layer 47 in a 12 layer PCB 45. The other 11 PCB layers are similar, but with the differences described below with respect to subsequent drawings. In the illustrated PCB layer 47, each trace 49 (which forms a single coil) includes a first terminal 51 at the outer edge of the coil and a second terminal 53 at the center of the coil. Trace 49 is connected to other traces 49 using vias 55. The first set of vias 55 is disposed adjacent to the first terminal 51 at the outer edge of each coil, and the second set of vias 55 is disposed adjacent to the second terminal at the center of each coil. In this embodiment, the trace 49 on the illustrated PCB layer 47 is not directly connected to the adjacent trace 49 on the illustrated PCB layer 47, but rather, as described more thoroughly in connection with FIG. , Respectively, directly connected to a corresponding trace 49 on a different PCB layer 47, as described more thoroughly in FIGS. 5 and 6A-6D.

In this embodiment, each trace 49 is continuous and without interruption from the first terminal 51 to the second terminal 53, the connection to these traces 49 is the first and second terminals 51, 53 It only takes place. Each trace 49 does not contain other terminals for electrical connection. In other words, each trace 49 can be seamlessly continuous without any other electrical connection by including an additional via 55 between the first and second terminals 51 and 53. As shown in Figure 4, the width of a given trace 49 may not be uniform. For example, the width 171 corresponding to the outer trace corner may be wider than the width 173 corresponding to the inner trace corner. The gap 175 between adjacent concentric trace portions forming a single coil may be the same as or different from the gap 177 between adjacent traces (ie, individual coils). In some embodiments, a given trace may include an outer width in a plane adjacent to the outer diameter of the PCB and perpendicular to the axis 35, and an inner width in the plane adjacent to the inner diameter of the PCB. In some embodiments, the outer width may be greater than the inner width. In some embodiments, a given trace may include inner and outer opposing edges that are not parallel to each other.

5 shows an embodiment of a 12 layer PCB 45 including the PCB layer 47 shown in FIG. 4. The twelve PCB layers 47 are each closely spaced and form a "sandwich" of the PCB layer 47 labeled 47.1-12. The top PCB layer 47.1 is shown with a first trace 49.11 (also referred to herein as "coil 49.11"), the first terminal 51.1 to the external terminal 61 for the device 31. Are combined. In the lowermost PCB layer 47.12 the trace 49.128 is shown with the first terminal 51.12 coupled to the external terminal 63 of the device 31. In this embodiment, there are 8 traces 49 (coils) in each of the 12 PCB layers 47.1-12. These traces are joined together (as described in more detail below) so that the current flowing to the external terminal 61 will flow through the 96 coils, then drain the external terminal 63 (or vice versa). Flows into and flows out of the external terminal 61). In this embodiment, only one trace 49 (e.g. coil 49.11) is coupled to the external terminal 61 for device 31, and only one trace 49 (e.g. Only the coil 49.128) is coupled to the external terminal 63 for the device 31. In the case of a motor, the external terminals 61 and 63 are both input terminals, and in the case of a generator, the external terminals 61 and 63 are all output terminals. As can be seen from this embodiment, each PCB layer is in the same plane and includes a plurality of coils symmetrically spaced apart from each other about an axis, and the coils of the PCB layers adjacent to the axis are symmetrical stacks of coils in the axial direction ( They are circumferentially aligned with each other with respect to the axis to define symmetric stacks).

FIG. 6A is an exploded view of a portion of the 12-layer PCB 45 shown in FIG. 5, which is labeled to better explain how the coils are joined together by vias 55, 59, so the current is 96 It is indicated to better explain how it flows through the two coils to the external terminal 63 and flows out to the external terminal 63. It is assumed that the input current 81.1 flows to the external terminal 61. This current flows "helically" around the coil 49.11 (PCB layer 47.1) as a current 81.2 (81.3) and reaches the second terminal 53 of the coil 49.11. Via 55.1 connects the second terminal 53 of the coil 49.11 to the second terminal of the corresponding coil 49.21 on the PCB layer 47.2 just below the coil 49.11. Thus, current flows through 55.1 with current 81.4 and spirals around coil 49.21 with current 81.5 until it reaches the first terminal 51 of coil 49.21. Via 55.2 connects the first terminal 51 of the coil 49.21 to the first terminal of the coil 49.12 on the PCB layer 47.1 adjacent to the first coil 49.11. In this embodiment, the traces 49 on the first PCB layer 47.1 are generally inverted (mirrorized) compared to the traces on the second PCB layer 47.2 so that vias 55.1 are of the coils 49.11 and 49.21. So that the two "taps" on the second terminal 53 overlap, and likewise, the via 55.2 overlaps the two "taps" on each of the first terminals 51 of the coils 49.12 and 49.21, which is subsequent to this. It is described in more detail below in connection with the drawings. Thus, the current flows as current 81.2 through 55.2 to the first terminal 51 of the coil 49.12 on the PCB layer 47.1.

At this terminal, current flows through coil 49.12 and coil 49.22 similar to that described for coil 49.11 and coil 49.21. For example, current flows around coil 49.21 (PCB layer 47.1) with currents 82.2 and 82.3 to second terminal 53 of coil 49.21, with current 82.4 through 55.3 of coil 49.22 through 55.3 2 flows to terminal 53, and then flows with currents 82.5 and 82.6 around coil 49.22 until it reaches the first terminal 51 of coil 49.22. As before, via 55.4 connects first terminal 51 of coil 49.22 to first terminal 51 of coil 49.13 on PCB layer 47.1 adjacent coil 49.12. This coupling configuration is replicated for all remaining traces 49 on the top two PCB layers 47.1, 47.2, and the current reaches the last coil 49.28 of the PCB layer 47.2 until the remaining coils 49.28 are reached. It flows through trace 49. The current already flows through all 16 coils of the upper two PCB layers 47.1 and 47.2 and then goes to the next PCB layer 47.3. Specifically, via 59.1 connects the first terminal 51 of the coil 49.28 to the first terminal of the coil 49.31 on the PCB layer 47.3 just below the coils 49.11 and 49.21. In this embodiment there are only these vias 59 that couple the coil on the PCB layer 47.3 to the coil on the PCB layer 47.3. Conversely, there are 15 such vias 55 that couple the coils together to the PCB layers 47.1 and 47.2. In this embodiment, this coupling occurs only at the first and second terminals 51 and 53 of the coil.

The via 55 between the third and fourth PCB layers 47.4 and 47.4 is configured identically to the via 55 between the first and second PCB layers 47.1 and 47.2 described above, and thus the via configuration and the corresponding current There is no need to repeat the flow. This continues down through the PCB layer "sandwich" until it reaches the lowest PCB layer 47.12 (not shown here). As described above, the first terminal 51 (49.128) for the trace (coil) is coupled to the external terminal (63). As a result, after flowing through all 96 coils, the current flowing inside through the external terminal 61 flows to the outside through the external terminal 63.

6B is an enlarged view of a group of vias 55 shown in FIG. 5. This via group is adjacent to each second terminal 53 for each group of coils 49.1-12 aligned vertically in each of the 12 PCB layers 47.1-12. As mentioned above, the trace 49 on the second PCB layer 47.2 is generally inverted (mirrorized) compared to the trace on the first PCB layer 47.1. Vias 55 overlap two "taps" on each second terminal 53 of these vertically adjacent coils. As shown in Fig. 6B, in the coil 49.18 (first layer, eighth coil), the second terminal 53.18 includes a tab extending to the side of the trace. In a mirror-image fashion, in the coil 49.28 (second layer, eighth coil), the second terminal 53.28 includes a tab extending in a direction opposite to the side of the trace, and these two tabs overlap. . Via 55 connects these two overlapping tabs together. In the same way, since the embodiment includes 12 PCB layers 47, the five additional vias 55 are respectively overlapping (overlapping) terminals 53.38 and (53.48), overlapping (overlapping) terminals, respectively. (53.58) and (53.68), overlapping (overlapping) terminals (53.78) and (53.88), overlapping (overlapping) terminals (53.98) and (53.108), overlapping (overlapping) terminals (53.118) and ( 53.128).

6C shows two of these vias 55 in an exploded form. Terminal 53.38 of coil 49.38 overlaps terminal 53.48 of coil 49.48 and is connected together by a first via 55. The terminals 53.58 of the coil 49.58 overlap with the terminals 53.68 of the coil 49.68 and are connected together by a second via 55. As can be clearly seen in the figure, these pairs of overlapping (overlapping) tabs are arranged radially staggered with the corresponding vias 55 such that these vias 55 can be implemented using plated through-hole vias. have. Alternatively, such vias 55 may be implemented as buried vias, in which case the vias do not need to be staggered, but rather can be vertically aligned.

6D is an enlarged view of a group of vias 59 shown in FIG. 5. In this embodiment, these vias 59 are placed between one particular adjacent pair of coils 49 (e.g., top layer coils 49.11 and 49.18) aligned vertically, while vias 55 ) Are placed in different gaps between different adjacent pairs of vertically aligned coils 49. In this figure, via 59 is shown as a plated through-hole via. Vias 55 and 59 overlap with two "taps" on each first terminal 51 of the corresponding coil. The via 55 connects a horizontally adjacent coil to a vertically adjacent layer, and the via 59 connects a horizontally aligned coil to a vertically adjacent layer, as shown in FIG. 6A. In this embodiment, there are only 5 vias 59, which has the first terminal 51 of the uppermost coil 49.11 connected to the external terminal 61, and the third of the coil 49.128 of the lowermost PCB layer 47.12. This is because the 1 terminal 51 is connected to the external terminal 63. Each first terminal 51 leaves only 10 PCB layers 47.2-11 with the coils joined together in pairs. For example, the innermost via 59.5 connects each coil of the PCB layer 47.10 to each coil of the PCB layer 47.11.

In various embodiments, each trace 49 may be electrically coupled to another trace 49 using at least one via 55. In the example of FIG. 6A, each PCB layer 47 has eight traces 49 and only one via 55 between the traces 49. In some embodiments, all traces 49 are electrically coupled to other traces 49. The two traces 49 together define a trace pair 57. In Figure 7, there are 12 PCB layers (47.1-12) and 6 trace pairs (57.1-6).

Each trace pair 57 may be electrically connected to another trace pair 57 via at least one via 59 (eg, just like one via 59). In some versions, the trace 49 (eg coil) of each trace pair 57 (eg coil pair) may be located on a different PCB layer 47, as shown in FIG. 6A. However, in other versions, the traces 49 of each trace pair 57 may be co-planar and may be located on the same PCB layer 47.

In some embodiments, at least two of the traces 49 (eg, coils) are electrically coupled in series. In another version, at least two of the traces 49 (eg a coil) are electrically coupled in parallel. In another version, at least two of the traces 49 are electrically connected in parallel and at least two other traces 49 are electrically connected in series.

An embodiment of the device 31 may include at least two pairs of traces 57 electrically connected in parallel. In another version, at least two of the trace pairs 57 are electrically coupled in series. In another version, at least two trace pairs 57 are electrically connected in parallel and at least two other trace pairs 57 are electrically connected in series.

4 to 6, each PCB layer 47 (only the upper PCB layer 47 is shown in the plan view) is the total surface area of the entire (upper) surface of the PCB 45: TSA), which is the PCB layer surface area (LSA). The TSA does not include holes in the PCB 45 such as the center hole and mounting hole shown. One or more traces 49 (the eight coils shown in Figure 4) on the PCB layer 47 may include the coil surface area (CSA). The CSA includes the "copper surface area" as well as the total footprint of the coil (ie, within the perimeter). CSA is at least about 50% of the surface area of the PCB layer, e.g., at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, about 90% or more, about 95% or more, about 97%, or even at least about 99%. In other embodiments, the coil surface area is 99% or less of the PCB layer surface area, such as about 95% or less, about 90% or less, about 85% or less, about 80% or less, about 75% or less, or even about 70% of the PCB layer surface area. May be less than or equal to %. In other embodiments, the coil surface area may be in a range between any of these values.

CSA can also be calculated with respect to any sensor or circuit (IOT element) on or inside the PCB. IOT devices can be limited to less than 50% of the TSA. Also, the IOT device may be included in the CSA or included in at least a portion of the TSA that is not included in the CSA.

The total area of each trace forming a coil (ie, including the conductive traces, but not necessarily the space between the conductive traces) can be viewed as the coil surface area. It is believed that the performance of the device 31 improves as the total coil surface area increases relative to the underlying PCB layer surface area on which the coil(s) are formed.

In some embodiments (FIG. 4), the device 31 may include a stator 41 comprising a single electric phase. The version of the stator 41 may consist of a single electric phase. Each PCB layer 47 may include a plurality of coils that are coplanar and symmetrically spaced about the axis 35 (FIGS. 2 and 3 ). In one example, each coil consists of a single electrical phase.

8 shows an embodiment of a stator 41 comprising at least two electrical phases (phases) (eg, three phases are shown). Each PCB layer 47 may include a plurality of coils (eg, traces 49) as shown for each electrical phase. For example, FIG. 8 shows coils corresponding to three phases A, B, and C. The coils for each electrical phase A, B, C are angularly offset from each other with respect to the axis 35 (Figures 2 and 3) within each PCB layer 47 to define the desired phase angular shift between electrical phases A and B. can be angularly offset). In FIG. 6, there are nine traces 49 on each PCB layer 47. The embodiment of the stator 41 of FIG. 8 is three-phase, each trace 49 of phase A is electrically 120 degrees apart from the other traces 49 in the case of phase A, and adjacent traces 49 in the case of phases B and C. ) And 40 degrees away. Traces 49 for phase B (for phases A and C) and phase C (for upper phases A and B) are likewise spaced.

In some embodiments, each coil (eg, trace 49) may consist of a single electrical phase. Alternatively, the coil may be configured to enable a stator 41 having two or more electrical phases (eg, three phases shown in FIG. 8).

The example of FIG. 9 is a simplified diagram of some internal components of an embodiment of the device 31. Each magnet 37 may include a magnet radial edge or element 67 (also referred to herein as a “magnet radial edge 67”), each of the traces 49 being a trace radial edge. (trace radial edge) or element 69 (herein "coil radial edge (69)"). The magnet 37 is part of the rotor 33 (FIG. 2) and rotates about an axis 35 with respect to the stationary stator 41. When the radial edge portions of the magnets 37 and traces 49 are rotationally aligned with respect to the axis during operation of the device 31, at least some of the radial elements 67, 69 will be warped relative to each other. Can (i.e. not parallel). In some embodiments, when the radial edge portions of the magnet and coil are rotationally aligned about an axis, the magnet radial edge and coil radial edge are not parallel but angularly skewed with respect to each other. 9 shows the rotational position of the magnet 37 in which the radial edge portion of the magnet 37 (i.e., the magnet radial edge 69 close to the corner of the magnet 37) is rotationally aligned with the radial edge portion of the coil 49. And shows the skew between the magnet radial edge 69 and the coil radial edge 67. In one version, the radial elements 67 and 69 may be a leading radial edge or a trailing radial edge of the magnet 37 and trace 49. In another example, the magnet and trace radial edges or elements 67, 69 may be linear as shown, and the magnet and trace radial elements 67, 69 when the magnets 37, 49 are rotationally aligned in the axial direction. No part of the is parallel.

In some embodiments, the magnet radial element 67 may be tilted at an angle with respect to the trace radial element 69, and each angular skew may be greater than 0 steps, for example greater than 0.1 degrees, at least about 1 degree. , At least about 2 degrees, at least about 3 degrees, at least about 4 degrees, or even at least about 5 degrees. In other versions, each skew is about 90 degrees or less, such as about 60 degrees or less, about 45 degrees or less, about 30 degrees or less, about 25 degrees or less, about 15 degrees or less, about 10 degrees or less, or about 5 degrees or less. Can be Alternatively, each angular skew can be in the range between these values.

In an alternative embodiment, at least some of the radial elements 67 and 69 may be parallel to each other during rotational alignment.

II. Segments

Some embodiments of the axial field rotational energy device may be configured in a manner similar to that described for device 31, including assembly hardware, except that the stator may be configured somewhat differently. For example, FIGS. 10-12 show a simplified version of the device 131 showing only some elements for ease of understanding. The device 131 may include a stator 141 coaxial with the rotor 133. Optionally, each rotor 133 may include one or more slits or slots 136 (FIG. 10) extending therethrough. In some versions, the slot 136 is angled with respect to the axis 135 (FIG. 12 ), and thus is simply not perpendicular. The angle of the slot 136 can be provided with a constant inclination, and can facilitate cooling air flow in the device 131. The slot 136 allows the air flow to be pushed or flowed through and/or around the rotor 133 and effectively cool the stator 141. Particularly in the embodiment with a plurality of stator segments, in particular in the embodiment with the inner diameter (R-INT) of the stator segment (Fig. 14) regardless of the outer diameter (R-EXT), the rotor spacer 143 ( Additional slots as shown in Fig. 12) may be provided in the rotor spacer.

Instead of including a single panel PCB 45 as described for stator 41, stator 141 may include a plurality of stator segments 142, each of which may be a separate PCB 145. The stator segments 142 may be joined together, such as mechanically and electrically coupled together. Each stator segment 142 may include a printed circuit board (PCB) having one or more PCB layers 147 (FIG. 13) as described elsewhere herein. In one example, each PCB 145 may have an even number of PCB layers 147. In an alternative embodiment, the PCB 145 may have an odd number of PCB layers 147.

Embodiments of the stator segment 142 may include or correspond to only one electrical phase. Moreover, the stator 141 of the device 131 may consist of or correspond to only one electric phase. In another version, the stator 141 may comprise or correspond to a plurality of electric phases. As shown in FIG. 13, each stator segment 142 includes at least one PCB layer 147 having at least one conductive trace 149 such as the illustrated coil. In some versions (Fig. 14), each stator segment 142 is at least having a plurality of traces 149 (e.g., coils) coplanar with each other and angularly spaced relative to the axis 135 (Fig. 14). It can have one PCB layer 147 (FIGS. 11 and 12 ). In one example, each trace 149 may comprise a single electrical phase. In another version, each stator segment 142 may include a plurality of PCB layers 147, each of which may be configured to correspond to only one electrical phase. In some versions, each PCB layer 147 on each stator segment 142 may include a plurality of axially coplanar traces 149 configured to correspond to only one electrical phase.

In some embodiments (Figure 13), each PCB layer 147 extends from about inner diameter (ID) of PCB 145 to about outer diameter (OD) of PCB 145. It may include at least one radial trace 150. In one example, each PCB layer 147 may include a continuous trace 149 from the outermost trace portion 152 to the concentric innermost trace portion 154. Traces 149 may include radial traces 150 with linear sides and chamfered corners 156. The linear side of the radial trace can be tapered and the width of the trace increases as the radial distance increases. Inner end turn traces 146 and outer end turn traces 148 extend between radial traces 150 to form a concentric coil.

With regard to tapered traces and coils, taper can improve the amount of conductive material (eg copper) that can be included in the PCB stator. Because many motors and generators form a round shape, the coils can generally be circular, and the circumference of the coils can be somewhat pie-slice-shaped or triangular in order to collectively engage the stator. . In some versions the coils can have the same width in a plane perpendicular to the axis, while in other versions the coils can be tapered to increase the density of the conductors in the coil (eg copper). Improving the copper density can be of significant value in reducing electrical resistance, I2R losses and heat generation, and increasing the ability to deliver higher currents to provide higher efficiencies to the machine.

In another version, each PCB layer 147 may contain only linear traces 149 (FIGS. 15-17). The linear trace 149 may be continuous from the outermost trace 152 to the concentric innermost trace 154. In one example, the trace 149 of the PCB layer 147 is not non-linear. However, embodiments of the only linear trace 149 may include rotations such as rounded corners or chamfered corners, for example. As used herein, “turn” includes a portion of a trace connecting a radial trace to an end turn trace. In other embodiments, the PCB layer 147 may include one or more nonlinearities, such as curvilinear traces.

As mentioned herein, the PCB 145 may include a plurality of PCB layers 147 spaced apart from each other in the axial direction. The PCB layer 147 may include a layer pair 157 (see FIG. 17; pair 157.1-157.4). Each layer pair 157 can be defined as two PCB layers electrically coupled together. In one version, at least one of the PCB layers 147 is electrically coupled to another PCB layer 147 in series or parallel. In another version, at least one layer pair 157 is electrically coupled to another layer pair 157 in series or parallel. In one embodiment, at least one of the layer pairs 157 includes two PCB layers 147.6 and 147.7 axially adjacent to each other. In another embodiment, at least one of the layer pairs 157 includes two PCB layers 147.1 and 147.3 that are not axially adjacent to each other. Similarly, at least one of the layer pairs 157 may be adjacent to the layer pair 157 to which at least one of the layer pairs is electrically coupled in the axial direction. Conversely, at least one of the layer pairs 157 may not be adjacent to the layer pair 157 to which at least one of the layer pairs 157 is electrically coupled in the axial direction.

An embodiment of the PCB layer 147 may include at least one set of layers 181 (FIG. 17). For example, the layer set 181 may include a first layer 147.1, a second layer 147.2, a third layer 147.3, and a fourth layer 147.4. In some versions, the first via 159 may couple the first layer 147.1 to the third layer 147.3, and the second via 155 connects the third layer 147.3 to the second layer 147.2. And the third via 159 may couple the second layer 147.2 to the fourth layer 147.4. In one example, the first, second and third vias 159, 155, 159 are the only vias that intra-couple the layer set 181. In this example, the two PCB layers 147.1 and 147.2 that are directly adjacent in the axial direction are not directly electrically coupled to each other. In FIG. 17, each via 159 couples a pair of non-adjacent PCB layers 147 while bypassing (ie, not in contact) an intervening PCB layer 147. For example, via 159.1 connects PCB layer 147.1 to PCB layer 147.3 and does not contact PCB layer 147.2. Conversely, each via 155 couples a pair of adjacent PCB layers 147. Via 155.2, for example, connects PCB layer 147.2 to PCB layer 147.3. Each via 155, 159 coupling each PCB layer pair together forms a corresponding layer pair 157. For example, layer pair 157.1 includes PCB layer 147.1 and PCB layer 147.3. Layer pair 157.2 includes PCB layer 147.2 and PCB layer 147.3. Layer pair 157.3 includes PCB layer 147.2 and PCB layer 147.4. Layer pair 157.4 includes PCB layer 147.4 and PCB layer 147.5. Layer pair 157.5 includes PCB layer 147.5 and PCB layer 147.7. Layer pair 157.6 includes PCB layer 147.6 and PCB layer 147.7. Layer pair 157.7 includes PCB layer 147.6 and PCB layer 147.8.

In Figure 17, each via is shown as having a blunt end and a pointed end. This shape does not imply a structural difference between the two ends of each via. Rather, it is intended to consistently indicate the direction of current flow through each via. Moreover, although each via is shown as extending vertically only as necessary to couple the corresponding pair of PCB layers 147, in certain embodiments each via is plated through-hole extending through the entire PCB. Through-hole) may be implemented as a via (eg, via 59 in FIG. 6D ). Each of these plated through-hole vias may contact any PCB layer 147 having a trace 149 overlapping such a via. As shown in Figure 17, a given through-hole via overlaps (overlaps) and makes a connection with only two PCB layers 147, while traces 149 of all other PCB layers 147 do not overlap a given via. Not connected to the given via. Alternatively, some embodiments may include buried vias extending vertically only between corresponding PCB layers 147 to be connected.

III. Modules

18, 19 and 20A-20H disclose an embodiment of a module 201 for one or more axial field rotational energy devices 231. Device(s) 231 may include any of the axial field rotational energy device embodiments disclosed herein. In the embodiment shown in these figures, the module 201 is a housing 203 having a side wall 211, three stators (shown as PCB stator panel 245) and four rotor assemblies 242, 244. Includes. Each rotor assembly 244 is disposed vertically between two stators 245 and includes a pair of identical rotor panels 236 and a group of rotor permanent magnets 237. Each rotor panel 236 includes a set of recessed indentations for positioning each rotor magnet 237, and two rotor panels 236 are opposed to the upper and lower rotors. They are fixed together to sandwich each group of rotor magnets between the panels 236. Each rotor assembly 242 is disposed vertically between the stator 245 and the housing 203 and includes a torque plate 233, a rotor panel 234 and a rotor permanent magnet group 237.

The vertical spacing between the rotor assemblies (e.g., 242, 244) is a spacer (e.g., 262, 263) extending from one rotor assembly to an adjacent rotor assembly through a hole in the inter-stator panel 245. Is maintained by The rotor spacing corresponds to the thickness of the stator panel 245 and the desired air gap spacing (eg, above and/or below) of the stator panel 245. Each rotor spacer can define a void between the rotor assembly and the stator (also can define the height 215 of the sidewall slots, as mentioned below). Each rotor spacer is located between two rotor assemblies. For example, the rotor spacer 262 is located between the top rotor assembly 242 and the adjacent inner rotor assembly 244 (and the same for the bottom rotor assembly 242). Each rotor spacer 263 is positioned between adjacent inner rotor assemblies 244. As shown here, this rotor spacer 263 may have a different thickness than the rotor spacer 262, and the mechanical difference between the top and bottom rotor assemblies 242 with respect to the inner rotor assembly 244 Due to this, it defines the same void spacing between all rotors and stators. The use of rotor spacers 262, 263 makes it possible to stack multiple rotors (eg, rotor assemblies 242, 244) that can provide considerable flexibility in the construction of module 201.

An embodiment of the housing 203 may include sidewalls 211 (FIGS. 20A-20H and 21 ). The sidewall 211 may be configured to orient the stator (eg, stator panel 245) in a desired angular orientation with respect to the axis 235. For applications that include a plurality of stators 245, the sidewall 211 may include a plurality of sidewall segments 212. The sidewall segments 212 may be configured to angularly offset the plurality of stators 245 at a desired electrical phase angle (see, eg, FIGS. 20C and 25) with respect to the module 201 with respect to the axis. In one example, sidewall 211 may include a radial interior surface having one or more slots 214 formed therein. Each slot 214 may be configured to receive and retain an outer edge of stator 245 to maintain a desired angular orientation of stator 245 with respect to axis 235. 20A-20H, each sidewall 211 includes three slots 214 formed between sidewall segments 212 of mating pairs. In some embodiments, the upper and lower sidewall segments 212 of these mating pairs are identical and thus may be used interchangeably, but in other contemplated embodiments the upper and lower sidewall segments 212 are asymmetric slots 214, mounted It may be different due to differences in hole placement or some other aspect.

In addition to providing the angular offset of the stator 245 as described above, the slot 214 is positioned in an axial direction such as vertical to position the outer edge of each stator 245 at a defined axial position relative to the other stator 41. It can be configured to let. Rotor spacers 262, 263 are each stator 245 (in the innermost extent) and a corresponding rotor assembly on the axial side of each stator 245 (e.g., 242 in FIGS. 20A, 20B and 20D). The combination of the sidewall slots 214 (i.e., the height 215 of these slots 214) and the rotor spacers 262, 263 is determined by the axial spacing between the stator 245 and the rotor. It serves to maintain the correct air gap between the electronic assemblies (242, 244). In another embodiment with a single stator 245, each sidewall segment 212 may be configured to provide one sidewall slot 214. The group of sidewall segments 212 provides together a number of slots 214 (eg, eight such slots 214) radially spaced around the module 201. Collectively, these sidewall slots 214 are stators. It can be seen as facilitating the void spacing between the and adjacent rotors.

The version of the module 201 has a mechanical feature configured to mechanically couple the housing 203 to the second housing 203 of the second module 201 (e.g., keyed shafts 209 in FIG. 21 ). ) May include a housing 203 having. Further, the housing 203 may be composed of an electrical element (eg, the electrical connector coupling 204 of FIGS. 21 and 22) to electrically couple the housing 203 to the second housing 203. In one example, module 201 is air cooled and not liquid cooled. In other versions, a water cooled embodiment could be used.

In some examples, module 201 may be configured to be indirectly coupled to second module 201 in an intervening structure such as frame 205 (FIGS. 21-22 ). The module 201 may be configured to be directly coupled to the frame 205, and the module 201 may be configured to be indirectly coupled to the second module 201 along with other components according to an application. In another example, the module 201 may be configured to be directly coupled to the second module 201 without a frame, chassis or other intervening structure.

In some embodiments, at least one stator 241 and at least one magnet 237 with at least one PCB 245 with at least one PCB layer 147 with at least one trace 149, and At least one rotor 233 may be located inside and surrounded by the housing 203.

In some versions, each module 201 consists of a single electric phase. In other versions each module 201 includes a plurality of electric phases. An example of each module 201 may include a plurality of PCB panels 245 (FIGS. 20A-20H). Each PCB panel 245 may include a single electric phase or a plurality of electric phases. The PCB panel may be a single panel or may include stator segments described elsewhere herein.

In one version, the module 201 and the second module 201 may be configured to be identical to each other. In other versions, module 201 and second module 201 may be different. For example, the module 201 may be different from the second module 201 by at least one of the following variables: power input or output, the number of rotors 233, the number of magnets 237, the number of stators 41 (See previous drawing), number of PCBs 245, number of PCB layers 47 (see previous drawing), number of traces 49 (see previous drawing), and angular orientation with respect to axis 235. For example, in some embodiments one or more of these variables may be modified to achieve a difference in power efficiency, torque, and achievable revolutions per minute (RPM). Thus, other modules 201 can be utilized to better tailor their operation as a function of load or other desired operating parameters.

Some embodiments of module 201 may include at least one latch 207 (FIGS. 23 and 24) configured to mechanically secure the modules together. FIG. 23 shows modules nested together with latch 207 open, and FIG. 24 shows modules nested together with latch 207 closed. In one example, the latches 207 can be arranged symmetrically about the axis 235. In other versions, the top module (not shown) can be configured axially on top of another module and the top module can be structurally different from the second module. For example, the upper module 201 may include the latch 207 only on the lower side thereof, and the latch 207 may be omitted on the upper side. As another example, shaft 209 may extend from lower module 201 but not from upper module 201.

21 to 24, the module 201 may include a key shaft 209. Module 201 may be mounted on a key shaft configured to mechanically couple to other modules 201.

Some embodiments may further include a body 213 (FIG. 26) (also referred to herein as an "enclosure"). The main body 213 may be configured to accommodate a plurality of modules 201 in the main body 213 and to be mounted coaxially. As illustrated, the body 213 includes two halves that are joined together with fasteners. For a version where each module 201 includes a single electrical phase, the body 213 may be configured to hold the module 201 at a desired electrical phase angle relative to the axis 235. In the case of a version in which the body 213 includes a plurality of electrical phases, the body 213 may be configured to hold the module 201 at a desired electrical phase angle with respect to the axis 235.

In other versions, there may be multiple bodies 213. Each body 213 has a coupling structure configured to mechanically couple each body 213 to at least one other body 213 and electrically couple each body 213 to at least one other body 213 Mechanical features such as electrical elements configured to be used. Each body 213 may be configured to be directly or indirectly coupled to at least one other body 213.

In some generator embodiments, the body (or one or more interconnected bodies) has multiple electrical phases (e.g., about 4 to 99, e.g., at least 10, 11, 12, 13, 14, 15 or And more). Thus, the AC current output can behave like a DC-like output ripple without rectification or power conversion. Other versions can rectify these AC current outputs.

An embodiment of a system for providing energy is also disclosed. For example, the system may include a plurality of modules 201 comprising an axial field rotational energy device. Modules 201 may be interchangeably connected to each other to configure a system for a desired power output. Each module may be configured based on any of the embodiments described herein. The system may include a generator or motor. An embodiment of the system may include at least two of the modules 201 configured to be different. For example, the module 201 can be different from each other by at least one of the following variables: power output or input, number of rotors, number of magnets, number of stators, number of PCBs, number of PCB layers, number of coils, and angle to axis. direction.

An embodiment of a method of repairing an axial field rotational energy device is also disclosed. For example, the method may include the following steps: Providing a body 213 having a plurality of modules 201. Each module 201 may be configured as described for any of the embodiments disclosed herein. The method also includes mechanically and electrically coupling the module 201 so that the module 201 is coaxial; Operating the axial field energy device; Detecting a problem with one of the modules 201 and deactivating the axial field energy device; Opening the main body 213 and separating the problem module 201 from all other modules 201 to which the problem module 201 is attached; Installing the replacement module 201 in the main body 213 instead of the problem module 201 and attaching the replacement module 201 to another module 201 to which the problem module 201 is attached; And then reactivating the axial field energy device.

Another embodiment of the method includes angularly aligning the module with respect to the axis with at least one desired electrical phase angle. In another version, the method may include providing a plurality of bodies 213 and mechanically and electrically coupling the bodies 213.

Another embodiment of a method of operating an axial field rotational energy device may include providing an enclosure having a plurality of modules. Each module is a housing, a rotor rotatably mounted in the housing-where each rotor is composed of a shaft and a magnet, and a stator mounted on the housing coaxially with the rotor-where each stator is a printed circuit board (PCB) having a coil Wherein each stator is composed of a single electric phase, and a selected stator of the stators is set at a desired phase angle with respect to the axis; Mechanically and electrically coupling the modules such that the modules are coaxial within the enclosure; The axial field energy device is then activated. That is, a single-phase machine can be formed by setting the single-phase stator to the same phase angle, and a multi-phase machine (or two or more) can be formed by setting the single-phase stator to various phase angles.

Optionally, the enclosure and each module may comprise a single electrical phase, and the method may include angularly aligning the module with a desired electrical phase angle with respect to the axis. The method may include an enclosure having a plurality of electrical phases, each module comprising a single electrical phase, and angularly orienting the module at a desired electrical phase angle with respect to the axis. The enclosure and each module may include a plurality of electrical phases, and the modules may be angularly misaligned with a desired electrical phase angle relative to the axis.

Some versions of the method may include providing a plurality of bodies, the method further comprising mechanically and electrically coupling the bodies to form an integrated system. Each module may include a plurality of stators angularly offset from each other with respect to the axis at the desired electrical phase angle. In one example, each stator consists of only one PCB. In another example, each stator includes two or more PCBs that are joined together to form each stator. In another version, the enclosure may have multiple electrical phases of alternating current (AC) output substantially equivalent to ripple, such as clean direct current (DC), without power conversion, as described herein.

In another version, a method of repairing an axial field rotational energy device comprises the steps of providing a plurality of bodies joined together, wherein each enclosure has a plurality of modules, each module being a housing, rotatably mounted to the housing. Including a rotor, the rotor includes a shaft and a magnet, the stator is mounted coaxially with the housing, and the stator includes a printed circuit board (PCB); Mechanically and electrically coupling the modules; Actuating the axial field rotational energy device; Detecting a problem with the first module in the first enclosure and deactivating the axial field rotational energy device; Opening the first enclosure and disassembling the first module from the first enclosure and any other modules to which the first module is attached; Installing a second module in the first enclosure instead of the first module and attaching the second module to any other module to which the first module is attached; And then operating the axial field rotational energy device again.

Since an embodiment of each module can have only one orientation within the enclosure, each module can be installed or removed from the enclosure in a single manner. The purpose of this design is to ensure that people working on the system cannot reinstall a new module on an existing system in the wrong location. This can only be done in one direction. This method may occur while the operation of AFRED is interrupted, and processing of the first module occurs without interrupting the other module and without modifying or affecting the other module.

27 shows another embodiment of a PCB stator 311 for an axial field rotational energy device as disclosed herein. The PCB stator 311 includes a substrate having one or more traces 313 that are electrically conductive. In the version shown, the PCB stator 311 includes eight coils of traces 313. Additionally, the PCB stator 311 may include one or more trace layers 313. The traces 313 of each layer are coplanar with the layer. Further, the traces 313 are arranged around the central axis 315 of the PCB stator.

28 is an enlarged plan view of a portion of the PCB stator of FIG. 27; In the illustrated embodiment, each trace 313 includes a radial portion 317 (relative to the axis 315) and end turns 319 extending between the radial portion 317. Each trace 313 may be divided into slits 321. In some versions, only the radial portion 317 includes a slit 321. The slit 321 can help reduce eddy current losses during operation. Eddy currents oppose the magnetic field during operation. Reducing the eddy current increases the magnetic strength and increases the efficiency of the system. Conversely, wide traces can produce eddy currents. The slit of the trace 313 can reduce the chance that an eddy current will be formed. The slits can allow current to flow more effectively through the traces 313.

An axial field rotational energy device may comprise a "smart machine" comprising one or more sensors integrated therewith. In some embodiments, such sensors may be configured to monitor, detect or generate data relating to the operation of the axial field rotational energy device. In certain embodiments, the operation data may include at least one of power, temperature, rotational speed, rotor position, or vibration data.

The version of the axial field rotational energy device may comprise an integrated machine comprising one or more control circuits integrated therewith. Another version of the axial field rotational energy device may comprise a fully integrated machine comprising one or more sensors and one or more control circuits integrated therewith. For example, one or more sensors and/or control circuitry may be integrated with the PCB and/or the housing. In the case of a motor embodiment, this control circuit can be used to drive or propel the machine. For example, in some motor embodiments, such control circuitry may include an input coupled to receive an external power source, and may also include an output coupled to provide current flowing through one or more stator coils. In some embodiments the control circuit is configured to supply torque and/or torque commands to the machine. In some generator embodiments, such control circuitry may include an input coupled to receive the current flowing through the coil, and may also include an output coupled to generate an external power source.

For example, one or more sensors and/or control circuitry may be integrated with the PCB stator 311. 29 shows another exemplary stator 340 with integrated sensors (eg 345, 346) attached to the top PCB layer 47. One of these sensors 342 is coupled to a secondary coil 344 that can be used to transmit and receive data to/from an external device, and can also be used to couple power to the sensor 342. have. In some embodiments, the secondary coil may be configured to use magnetic flux generated during operation to provide power to the sensor 342. In some embodiments, the secondary coil may be configured to receive inductively coupled power from an external coil (not shown). The secondary coil 344 may also be referred to herein as a micro-coil or small coil, since in certain embodiments this secondary coil may be much smaller than the stator coil 49, but relative size inference is not intended. . Rather, this secondary coil 344 is distinguished from the stator coil 49 which cooperates with the rotor magnet as described above. This secondary coil integrated with the PCB stator 311 may be placed on the PCB stator 311 in certain embodiments (e.g., manufactured or attached on the top PCB layer 47 of the PCB stator 311). being). This secondary coil integrated with the PCB stator 311 may be placed within the PCB stator 311 (ie, embedded inside) in certain embodiments. In some embodiments, the secondary coil 344 provides power to a sensor connected thereto. This combined power can be the primary or auxiliary power of the sensor.

The sensor 346 is coupled to the first terminal 51 for one of the traces 49 on the upper PCB layer 47, and at that location can sense operating parameters such as voltage and temperature, and the attached coil ( For example, it may be powered by one of the coils 49). The sensor 348 is coupled to the external terminal 350, similarly can detect operating parameters such as voltage and temperature at that location, and may be powered by a voltage coupled to the external terminal 350. . The sensor 350 is placed on the outer edge of the PCB stator 340 but is not coupled to any conductor on the PCB layer 47.

In some embodiments, such a sensor may be embedded directly in one of the coils 49 and may be electrically powered directly by the coil 49. In some embodiments, such a sensor is powered by a separate connection disposed on or inside the PCB layer 47, such as a connection between the first terminal 51 and the sensor 346, and is connected to the coil 49. Can be connected. This connection can be placed on the PCB layer 47 or in the PCB (eg, on the inner layer of the PCB). In other embodiments, the sensors and/or circuits may obtain power from an external power source. For example, one type of external power source can be a conventional wall electrical socket that can be coupled to the housing of a motor or generator.

The sensors may provide real-time operational data to an operator of a generator or motor product, as well as predictive data for various parameters of the product in certain embodiments. This may include how the equipment works, and the schedule and timing of maintenance. This information can reduce product downtime and extend product life. In some embodiments, the sensor may be integrated within the housing. In some examples, the sensor may be embedded within the PCB stator 340 as shown in FIG. 30 (eg, 362, 366, 368, 372 and coil 364).

One example of a sensor for this application is a Hall effect sensor. Hall effect sensors are used in proximity switching, positioning, speed sensing and current sensing applications. In its simplest form, the Hall-effect sensor acts as an analog converter and returns the voltage directly.

Another example of a sensor is an optical sensor. The optical sensor can measure the intensity of electromagnetic waves in a wavelength range between ultraviolet and near infrared rays. The basic measuring device is a photodiode. Pixels are created by combining photodiodes and electronic devices. In one example, the optical sensor may include an optical encoder that measures or detects the position of the magnetic rotor using an optical device.

Another example of a sensor is a thermocouple sensor for measuring temperature. Thermocouples consist of two wire legs made of different metals. Wire legs are welded together at one end to create a joint. The junction is where the temperature is measured. When the junction experiences a temperature change, a voltage is generated.

Another optional sensor is an accelerometer. Accelerometers are electromechanical devices used to measure acceleration forces. These forces can be static, such as constant gravity, or they can detect motion or vibration dynamically, as is the case with many mobile devices. Acceleration is the change in speed or speed divided by time.

Gyro sensors that function like gyroscopes can also be used in these systems. Gyro sensors can be used in navigation systems, autopilots and stabilizers to provide stability or maintain reference orientation.

The PCB stator 340 may also include a torque sensor. A torque sensor, torque transducer, or torque meter is a device that measures and records torque in a rotating system, such as an axial field rotational energy device.

Another optional sensor is a vibration sensor. Vibration sensors can measure, display and analyze linear velocity, displacement and proximity or acceleration. Vibration, even minor vibrations, can be a signal to the state of a machine.

In various embodiments, the sensors shown in FIGS. 29 and 30 may represent a control circuit integrated with the PCB stator 45. These control circuits may be placed on the surface of the PCB (similar to the sensor shown in Fig. 29) or within the PCB (similar to the sensor shown in Fig. 30) (i.e. embedded inside) and/or a housing (e. , The housing 203 of Fig. 18) and or is integrated therein.

In some generator embodiments, the control circuit may implement power conversion from an AC voltage generated in the stator coil to a desired external power source (eg, an AC voltage different from the coil voltage, a DC voltage generated by rectifying the coil voltage). In some motor embodiments, the control circuit may implement an integrated drive circuit capable of providing a desired AC current waveform to the stator coil to drive the motor. In some examples, the integrated drive may be a variable frequency drive (VFD) and may be integrated within the same housing as the motor. The sensors and/or circuits disclosed herein may be wirelessly or wiredly connected to the interior, interior, or any element within the housing. Alternatively, the sensor and/or circuit can be located remotely with respect to the housing. In one example, the control circuit 566 (FIG. 39) may include a circular toroidal shape similar to the PCB stator shown in the figure. Such a design may allow and/or enable the device to maintain a form factor.

Each of these sensors and control circuits may include a wireless communication circuit configured to communicate with an external device through a wireless network environment. Such wireless communication may be one-way or two-way, and may be useful for system status monitoring, system operation, and predictive data communication. Wireless communication over the network is, for example, LTE, LTE-advanced (LTE-A), code division multiple access (CDMA), wideband CDMA (WCDMA), universal mobile communication system (UMTS), wireless broadband (WiBro), or mobile. It may be performed using at least one of a global system for communication (GSM) and a cellular communication protocol.

Additionally or alternatively, wireless communication may include, for example, short-range communication, and short-range communication may include, for example, ^{at least one of WiFi, Bluetooth ®} , short-range wireless communication (NFC) or GNSS. The GNSS may include, for example, at least one of GPS (Global Positioning System), Glonass® Global Navigation Satellite System, Beidou® Navigation Satellite System, or Galileo®, a global satellite-based navigation system. In this specification, the terms'GPS'and'GNSS' are used interchangeably. The network may be one or more of a communication network, for example a computer network (eg, a local area network (LAN) or a wide area network (WAN)), the Internet, or a telephone network.

In certain embodiments, such wireless communication circuitry may be coupled to a secondary coil (eg, secondary coil 344) to communicate telemetry information, such as operation data described above.

31 and 32 show an embodiment of an assembly for mechanically joining the stator segments 380 together to form a stator. A clasp 382 slides over a portion of the mounting pad 381 on two adjacent stator segments 380, which is attached to a pair of nuts on each of the two bolts (e.g., bolts 384). Is fixed by The clasp 382 includes an alignment tab 392 that can be positioned in the sidewall slot 214 as described above. The inner diameter edges of two adjacent stator segments 380 slide into a channeled rotor spacer 390 in the form of an annular ring. In some embodiments, the rotor spacer 390 may ride on a thrust bearing together with the rotor so that the rotor spacer 390 and the stator remain fixed while the rotor is rotating. . In another embodiment, the rotor spacer as described above (eg, FIGS. 18, 20A-20H) may be fitted within the open center of the channel-type rotor spacer 390.

Electrical connections between adjacent stator segments 380 and 381 may be implemented using wires 387 between respective circuits 386 and 388. Circuit 386 may be connected to a trace on an upper layer of stator segment 380 (or another layer using vias). Similarly, circuit 388 may be connected to any layered trace of stator segment 381. Such circuits 386 and 388 may include any of the sensors described above (FIGS. 29-30), but may simply provide an electrical connection from each PCB to wires 387. In other embodiments, the electrical connection may also be made through the mounting surface of the PCB, which is a conductive material, connected to the coil, and then joined these components through a clasp that may include a conductive material on its inner surface.

Electrical connection may also be implemented using a clasp 382 coupled with an electrically conductive mounting pad 383. When the mounting pad 383 is continuous and unbroken, the clasp 382 can provide a common electrical connection around the circumference of the stator. If such mounting pads are discontinuous and separated into two pieces (as indicated by the dotted lines, each piece is coupled to each terminal of the trace on that segment), the clasp 382 can connect these stator segments in series.

The axial field rotational energy device is suitable for many applications. The PCB stator 340 can be configured for a desired power reference and form factor for devices such as permanent magnet generators and motors. These designs are lighter in weight, easier to produce, easier to maintain, and more efficient.

Examples of permanent magnet generator (PMG) applications may include: wind turbine generators, micro generator applications, permanent magnet direct drive generators, steam turbine generators, hydro generators, heat generators, gas generators, firewood generators. , Coal generators, high frequency generators (e.g. frequencies above 60 Hz), portable generators, auxiliary power units, automobiles, alternators, regenerative braking devices, PCB stators for regenerative braking devices, backup or standby power generation, PMG for backup or standby power generation, military use PMG and PMG for aerospace.

In other embodiments, examples of permanent magnet motors (PMMs) may include: AC motors, DC motors, servo motors, stepper motors, drone motors, household appliances, fan motors, microwave ovens, vacuums. Drivetrains for machinery, automobiles, electric vehicles, industrial machinery, production line motors, IoT sensors (IOT) support, heating, ventilation and air conditioning (HVAC), HVAC fan motors, laboratory equipment, precision motors, motors for military, autonomous vehicles, Aerospace and aircraft motors.

33 and 34 show another embodiment of an axial field rotational energy device 401. In this example, device 401 may include any of the features, elements, or components disclosed herein. The illustrated version may include a housing having an axial axis 405 (eg, housing 203 in FIG. 18 ). The stator assembly 411 may include a plurality of stator panels 445 which are panels separated from each other. The stator panel 445 may be mechanically fixedly coupled to the housing. Each stator panel 445 may include a printed circuit board (PCB) having coils that are electrically conductive as disclosed herein. An embodiment of each stator panel 445 may be configured with a single electric phase. The device 401 may also include a rotor 442 rotatably mounted within a housing on opposite axial ends of the stator assembly 411. The rotor 442 may be mechanically coupled with components such as the rotor spacer 443. The version of each rotor 442 may include a magnet 437. In some examples, the rotor 442 is not disposed between axially adjacent stator panels 445.

The stator panel 445 may be coupled in a contact relationship in the axial direction. Moreover, the stator panels 445 may be directly mechanically coupled to each other in an axial contact relationship. Further, the stator panel 445 may be rotationally aligned at a single angle with respect to the axis 405. In some examples, stator panels 445 may be electrically coupled together to form a single electrical circuit for device 401. In another embodiment of the device 401, no axial spacers are disposed between the axially adjacent stator panels 445. As shown and described for other examples herein, the coils of the stator panel 445 may extend in a radial direction with respect to the axis 405, and each coil may include an edge extending in the radial direction, The coil edges can be substantially parallel to each other. That is, the coils may have inner and outer opposite edges that are parallel to each other.

An embodiment of the device 401 may include a stator assembly 411 having a plurality of electrical phases. The stator panels 445 may be rotationally offset from each other with respect to the axis 405. In some examples, stator panels 445 are not electrically coupled together to form a single electrical circuit for device 401. In one particular version, the stator assembly 411 may consist of only three stator panels 442. In another specific example, the rotor 442 may consist of only two rotors 442. The device 401 may further include a spacer (not shown) of any type (eg, metal, paper, etc.) disposed between adjacent stator panels 445 in the axial direction. An embodiment of the device 401 may further include an axial spacer (not shown) between the stator assembly 411 and the rotor 442. The version of the axial spacer can set the axial clearance gap between the stator assembly 411 and the rotor 442.

As shown in FIG. 35, the embodiment of the coil 459 may be arranged asymmetrically around the axis 405. In some versions, each stator panel 455 includes an inner radius (IR), an outer radius (OR), and a slot (S) that extends continuously in a radial direction between the inner radius (IR) and the outer radius (OR). can do. In one example, the slot S has a circumferential width about the shaft 405 that is not less than the diameter of the rotor spacer (e.g., rotor spacer 443 in FIG. 33) that couples the rotor 442 together. W) may be included. The embodiment of the slot S may be defined by side walls 453 parallel to each other, and the circumferential width W may be consistent from the inner radius IR to the outer radius OR. In such a version, the slot S can be configured to remain empty and unencumbered during the operation of the device 401, such that other components during the operation of the device 401 Make sure not to be located inside.

Alternatively, as shown in Fig. 36, an alternative embodiment of the slot S may be defined by a non-parallel side wall 463, the circumferential width W being the outer radius from the inner radius IR Taper to (OR). In some embodiments, at least one of the coils 469 of each stator panel 465 is a stator panel segment 468 comprising another PCB that is mechanically and electrically coupled to the respective stator panel 465, respectively. It can be located on. An example of each stator panel 465 is a stator assembly 411 (see, e.g., FIGS. 33 and 34) through a slot S without disassembling the rotor 442 from the axial field rotational energy device 401. ) Can be configured to be individually removed from. Further, each of the stator panel 465 and the stator panel segment 468 can be mounted to each other in a coplanar arrangement, for example.

In certain embodiments, the device 401 may include a plurality of stator panels and an inconsistent number (number) of rotors. For example, the device may have 2 stator panels and 1 rotor, 3 stator panels and 2 rotors, 5 stator panels and 2 rotors, and the like. In some versions, the rotor is not inserted into the stator assembly 411 (ie, axially disposed between adjacent panels in the axial direction of the stator panel). Moreover, device 401 may comprise a single electric phase or more than one electric phase. Other embodiments may include an enclosure having two or more devices 401 (which may be the same) located within the enclosure.

37 is an enlarged partial plan view of another embodiment of the stator panel 475. An example of the coil 476 of the stator panel 475 may have a higher density of copper adjacent the respective inner and outer diameter portions 477, 478, and will be further away than the inner and outer diameter portions 477, 478. Can be compared to the radial portion 479.

38 is an enlarged partial plan view of another embodiment of the stator panel 485. An example of a stator panel 485 may have a variable number of slits in the radial trace 489 of the coil 486. For example, the radial trace may include 2, 3, 4, 5 or more slits within the same radial trace 489 as shown.

39-46 show another embodiment of an axial field rotational energy device. Any of the elements, features, and components described herein for other versions of the device may also be used in these embodiments. In some versions, the axial field rotational energy device 501 may include a housing 503 having an axial axis 505 (eg, housing shells 503a and 503b in FIG. 39 ). The housing shells 503a and 503b can be joined together. Each housing shell 503a, 503b may include an internal perimeter 507 having an axial shelf 504 formed therein.

An example may include a stator assembly 511 mounted on the housing 503. The stator assembly 511 may include a plurality of stator panels 545 stacked in the axial direction and separated from each other. Each stator panel 545 may include a respective printed circuit board (PCB) having a respective plurality of coils that are electrically conductive and interconnected within each PCB, as described elsewhere herein. Each PCB may be configured such that a current flowing through any one of the plurality of coils likewise flows through all of the plurality of coils. In one example, each stator panel 545 may consist of a single electric phase.

Each version of stator panel 545 may include two identical C-shaped PCB segment halves 545a, 545b (FIGS. 44 and 45 ). PCB segment halves 545a, 545b can be joined together (via electrical connector 554; as shown in FIG. 44) to form respective stator panels 545. The electrical connector may be a U-shaped wire clip for each assembly and disassembly. In the illustrated example, there are three stator panels 545 in the stator assembly 511 for a total of six PCB segment halves 545a, 545b that are identical to each other and are interchangeable within the system. In addition, in this figure, the three stator panels 545 can be offset by P1 and P2, which exposes the wire clip area on the lower stator panel 545 so that the connector 554 is from above for ease of assembly and disassembly. Allow it to be inserted.

In some versions, the stator panels 545 are to each other and at least one axial shelf 504 (FIG. 39) using fasteners 506 in an axial-abutting relationship for enhanced thermal conductivity. ) Is mechanically coupled. The stator assembly 511 may be mechanically coupled to at least one of the axial shelves 504. Further, the stator panel 545 may have an outer peripheral edge contacting radially inner surfaces of the housing shells 503a and 503b at the inner periphery 507. Moreover, thermal putty can also be used on the contact surface to improve heat transfer between the PCB and the housing 503. Housing 503 may further include external fins 508 as a substrate design to provide additional cooling for device 501.

Each stator panel 545 has a single angle relative to the axis 505 to form (a) a rotationally aligned single electrical phase device, or (b) a plurality of stator panels 545 with respect to the axis 505. It may further include a plurality of perimeter mounting holes 547 (FIGS. 44 and 45) configured to form a multi-phase device with rotational offset (FIG. 44) from each other at the desired phase angles P1 and P2.

Embodiments may further include a rotor assembly having one or more rotors 542 (FIGS. 39 and 41-43) rotatably mounted within the housing 503. The former 542 may be located at an opposite axial end of the stator assembly 511. The rotors 542 may be mechanically coupled together. Each rotor 542 may include a plurality of magnets 537. In some versions (FIG. 41 ), magnet 537 may include leading and trailing edges 539. The leading edge 539 of one magnet may be parallel to the trailing edge of an adjacent magnet 537 to define a consistent circumferential spacing about the axis 505 between adjacent magnets 537. The device 501 consisting of the parallel leading and trailing edges 539 of the magnet 537 is, for example, having non-parallel leading and trailing edges 69 on adjacent ones 37 of the magnets 37. It is possible to increase the magnetic flux capacity of the device 501 by about 3% compared to a device having a magnet 37 (FIG. 9).

An embodiment of the magnet 537 may have a trapezoidal shape as shown. The version of each magnet 537 may include an inner radial edge 538 (FIG. 41) parallel to its outer radial edge 540 with respect to the axis 505. The magnet 537 may include an even or odd number of magnets 537. With respect to the axis 505, one of the magnets 537 adjacent in the circumferential direction includes opposite magnetic poles. In the opposing rotor 542, the opposite of the magnets 537 may include opposing magnetic poles.

In some embodiments (Figures 42, 43 and 46), each rotor 542 is a rotor hub having a magnetic backing 546 mounted on one axial side of the rotor hub 544. (544) may be included. The magnet 537 may be mounted on the opposite side of the rotor hub 544 in the axial direction. Collectively, Figure 42 shows the magnet inner radius or diameter (MID) and magnet outer radius with respect to the axis 505 to define the magnet radial span 560 by the magnet 537. Or, it exemplifies how to define the magnet outer radius or diameter (MOD). The magnetic backing 546 may include a backing inner radius or diameter (BID) smaller than the magnet inner diameter MID. Additionally or alternatively, the magnetic backing 546 may have a backing outer diameter (BOD) greater than the magnet outer diameter MOD to define a backing radial span 561. have. In addition, the backing outer diameter (BOD) may be flush with the outer circumference of the rotor hub 544 as shown.

In another example, the rotor hub 544 has a larger magnetic backing (support) 548 as well as a smaller magnetic backing (support) 548 located directly (axially) between the magnet 537 and a larger magnetic backing (support) 546. It may have a magnetic backing (support) 546. The smaller magnetic backing 548 can define a smaller backing radial span 562. The magnetic backings 546 and 548 may be a single monolithic layer, a plurality of stacked layers (as shown), and may include any magnetic material including carbon, silicon, ferromagnetic materials, and the like. A version of the rotor hub 544 may include a trapezoidal hole 550 (FIG. 46) for each magnet 537. The magnet 537 can be fixed to the rotor hub only by magnetic attraction to the magnetic backings 546 and 548 in one version. In other versions, adhesives can also be used.

The rotor assembly may include various hardware for connecting the rotor 542 to the shaft 551. For example, Figures 39, 42 and 45 show a quad-split-ring clamp structure 553 capable of fixing the rotor hub 544 to the shaft 551 with fasteners. . The rotor hub 544 may include an inner bevel to receive outer beveled versions of the quad split ring clamp structure 553. Shaft bearings may rotatably mount the shaft 551 and the rotor assembly to the housing.

Another embodiment of the device 501 may include a stator panel 545 having a plurality of cores 580 (FIGS. 44-45 ). Each core 580 may include a magnetic material (eg, carbon steel, iron, ferrite, etc.) and various shapes, such as the trapezoid shown. Each core 580 may be located at the center 582 of each coil 549 of the stator panel 545. Core 580 may be electrically insulated from coil 549. Versions of core 580 may include one or two axial surfaces flush or substantially flush with each axial surface of stator panel 545.

In some examples, the center 582 of each coil 549 can include a volume (eg, a concave volume) located inside the innermost trace 552 of each coil 549.

In one version, the volume may be formed during the fabrication of the PCB of the stator panel 545 so that the core 580 can be included during the fabrication of the PCB. In another version, the volume may be removed from the PCB after the PCB is manufactured, so that the core 580 is added to the PCB after the PCB manufacturing. The magnetic core 580 may increase the magnetic flux capacity of the device 501, which may allow the use of weak magnets while maintaining the high efficiency of the device 501, and/or the diameter of the device 501 It can be smaller without degradation.

Other versions may include one or more of the following embodiments:

1. In the axial field rotational energy device,

A rotor including a rotating shaft and a magnet;

The stator coaxial with the rotor, the stator includes a printed circuit board (PCB) having a plurality of PCB layers spaced apart in an axial direction, and each PCB layer is composed of a coil having only two terminals for electrical connection, and each coil Is continuous and uninterrupted between only two terminals, each coil consists of a single electrical phase, and one of the two terminals of each coil is electrically coupled to the other via a via to define a coil pair; And

Each pair of coils is electrically coupled to another pair of coils with other vias.

2. The axial field rotation energy device of any of these embodiments, wherein each PCB layer comprises a plurality of coils, and the coils of each coil pair are coplanar and located on the same PCB layer.

3. The axial field rotational energy device of any of these embodiments, wherein the coils in each coil pair are located on a different PCB layer.

4. The axial field rotational energy device of any of these embodiments, wherein at least two of the coils are electrically connected in series.

5. The axial field rotational energy device of any one of these embodiments, wherein at least two of the coils are electrically connected in parallel.

6. The axial field rotational energy device of any one of these embodiments, wherein at least two of the coils are electrically connected in parallel and the other at least two of the coils are electrically connected in series.

7. The axial field rotational energy device of any of these embodiments, wherein at least two pairs of coils are electrically connected in parallel.

8. The axial field rotational energy device of any one of these embodiments, wherein at least two pairs of coils are electrically connected in series.

9. The axial field rotation energy device of any one of these embodiments, wherein at least two pairs of coils are electrically connected in parallel and at least two pairs of coils are electrically connected in series.

10. Of these embodiments, each PCB layer includes a PCB layer surface area, and the coils on each PCB layer include a plurality of coils having a coil surface area ranging from at least about 75% to about 99% of the PCB layer surface area. Any one axial field rotational energy device.

11.Each PCB layer is coplanar and contains a plurality of coils symmetrically spaced about an axis, and the coils of the PCB layers adjacent to the axis are circumferentially circumferential to each other to define a symmetric stack of coils in the axial direction The axial field rotational energy device of any of these embodiments, aligned in the direction.

12. The axial field rotational energy device of any of these embodiments, wherein the stator comprises at least a single electrical phase.

13. The axial field rotational energy device of any of these embodiments, wherein the stator comprises at least two electrical phases.

14. Each PCB layer contains a plurality of coils for each electrical phase, and each electrical phase coil is each offset from each other with respect to the axis within each P{CB layer, to define the desired phase angle between the electrical phases. The axial field rotation energy device of any of the examples.

15. The axial field rotational energy device of any of these embodiments, wherein the stator comprises a single unitary panel.

16. The axial field rotational energy device of any of these embodiments, wherein each coil is coupled to another coil with only one via.

17. The axial field rotation energy device of any of these embodiments, wherein each coil pair is coupled to another coil pair with only one via.

18. The axial field rotational energy device of any of these embodiments, wherein the via comprises a plurality of vias.

19. The axial field rotational energy device of any of these embodiments, wherein the other via comprises a plurality of vias.

20. The axial field rotational energy device of any one of these embodiments, wherein the axial field rotational energy device is a generator.

21. The axial field rotation energy device of any of these embodiments, wherein the axial field rotation energy device is a motor.

22. The axial field rotational energy device of any one of these embodiments, wherein the axial field rotational energy device comprises at least two electrical phases and at least two external terminals.

23. The axial field rotational energy device of any of these embodiments, wherein the coils are identical to each other.

24. The axial field rotation energy device of any one of these embodiments, wherein the at least two coils are not identical to each other and are at least different in size or model from each other.

25. In the axial field rotational energy device,

A rotor including a rotating shaft and a magnet; And

A stator coaxial to the rotor, wherein the stator comprises a PCB comprising a plurality of axially spaced PCB layers, each PCB layer comprising a coil, and the plurality of PCB layers:

It includes a plurality of coil layer pairs, the coils of each coil layer pair are on different PCB layers, at least two of the coil layer pairs are connected together in parallel, and at least the other two of the coil layer pairs are connected together in series. do.

26. The axial field rotational energy device of any of these embodiments, wherein the stator comprises at least two electrical phases.

27. Each PCB layer contains a plurality of coils for each electrical phase, and the coils for each electrical phase are angularly offset from each other with respect to the axis within each PCB layer to define the desired phase angular shift between electrical phases. The axial field rotational energy device of any of these embodiments.

28. The axial field rotational energy device of any of these embodiments, wherein each coil comprises a single electrical phase.

29. In the axial field rotational energy device,

A rotor including a rotating shaft and a magnet;

A stator coaxial to the rotor-wherein the stator comprises a printed circuit board (PCB) having a first PCB layer and a second PCB layer spaced apart from each other in an axial direction, each PCB layer comprising a continuous coil, Each coil has only two terminals for electrical connection; And

The one via electrically couples the coils through one terminal of each coil.

30. In the axial field rotational energy device,

A rotor including a rotating shaft and a magnet;

A stator coaxial with the rotor, the stator includes a printed circuit board (PCB) consisting of a single unitary panel having two or more electrical phases, and the PCB includes a plurality of PCB layers spaced apart in the axial direction. Each PCB layer consists of a plurality of coils, each coil has only two terminals for electrical connection, each coil is continuous and uninterrupted between only two terminals, and each coil consists of a single electrical phase. And one of the two terminals of each coil is electrically connected to the other coil with only one via to define the coil pair, and each coil pair is electrically connected to the other coil pair using the other via;

The coils of each PCB layer are coplanar and symmetrically spaced about the axis, the coils of adjacent PCB layers are circumferentially aligned with each other to define a symmetrical stack of coils in the axial direction;

Each PCB layer contains a plurality of coils for each electrical phase, and the coils for each electrical phase are angularly offset from each other with respect to the axis within each PCB layer to define the desired phase angular shift between electrical phases.

1. In the axial field rotational energy device,

A rotor including a rotating shaft and a magnet; And

A stator coaxial to the rotor, the stator includes a plurality of stator segments coupled together with respect to the axis, each stator segment including a printed circuit board (PCB) having a PCB layer including a coil, each of the stator segments The stator segment contains only one electrical phase.

2. The axial field rotational energy device of any of these embodiments, wherein the stator constitutes only one electrical phase.

3. The axial field rotational energy device of any of these embodiments, wherein the stator comprises a plurality of electrical phases.

4. The axial field rotational energy device of any of these embodiments, wherein the coils are identical to each other.

5. The axial field rotation energy device of any of these embodiments, wherein each PCB layer is coplanar and includes a plurality of coils spaced at an angle from one another with respect to the axis.

6. The axial field rotational energy device of any of these embodiments, wherein each stator segment comprises a plurality of PCB layers, each configured to provide the only one electrical phase.

7. The axial field rotational energy device of any of these embodiments, wherein each PCB layer on each stator segment is coplanar and comprises a plurality of coils configured to provide the only one electrical phase.

8. The axial field rotational energy device of any of these embodiments, wherein each coil includes a radial trace extending from about the inner diameter of the PCB to about the outer diameter of the PCB.

9. Each coil contains a continuous trace from the outermost trace portion to the concentric innermost trace portion, and the coil comprises a radial element having linear sides and turns. One axial field rotational energy device.

10. Each coil contains only continuous linear traces from the outermost trace to the concentric innermost trace, and the traces on the PCB layer are not linear, and each coil contains a corner for joining a unique linear trace. Any one of the axial field rotational energy devices.

11. Of these embodiments, each PCB layer comprises a PCB layer surface area, and the coils on each PCB layer comprise a plurality of coils having a coil surface area in the range of at least about 75% to about 99% of the PCB layer surface area. Any one axial field rotational energy device.

12. Each PCB layer contains a plurality of coils that are coplanar and symmetrically spaced about an axis, and the coils of adjacent PCB layers are axially aligned with each other to define a symmetrical stack of coils. The axial field rotational energy device of any of these embodiments, aligned in the circumferential direction.

13. In the axial field rotational energy device,

A rotor including a rotating shaft and a magnet;

A stator coaxial to the rotor,-where the stator is

The stator includes a plurality of stator segments coupled together around an axis, each stator segment includes a printed circuit board (PCB) having a plurality of PCB layers each containing a coil, and the PCB layers are spaced apart from each other in the axial direction. Each PCB has an even number of PCB layers, a PCB layer consists of a pair of layers, each layer pair is defined as two PCB layers electrically connected with a via, and each layer pair is a different via and a different layer pair. Is bound to

14. The axial field rotation energy device of any of these embodiments, wherein the at least one PCB layer is electrically coupled in series with another PCB layer.

15. The axial field rotation energy device of any of these embodiments, wherein the at least one PCB layer is electrically coupled in parallel with another PCB layer.

16. The axial field rotational energy device of any one of these embodiments, wherein the at least one layer pair is electrically coupled in series with the other layer pair.

17. The axial field rotational energy device of any of these embodiments, wherein the at least one layer pair is electrically coupled in parallel with the other layer pair.

18. The axial field rotation energy device of any one of these embodiments, wherein the at least one layer pair comprises two PCB layers axially spaced from each other and axially adjacent.

19. The axial field rotational energy device of any one of these embodiments, wherein at least one of the layer pairs comprises two PCB layers that are not axially adjacent to each other.

20. The axial field rotational energy device of any one of these embodiments, wherein at least one of the layer pairs is axially adjacent to the layer pair to which at least one of the layer pairs is electrically coupled.

21. The axial field rotational energy device of any one of these embodiments, wherein at least one layer pair is not axially adjacent to the layer pair to which the at least one layer pair is electrically coupled.

22. The axial field rotational energy device of any of these embodiments, wherein the coils are identical to each other.

23. The axial field rotational energy device of any one of these embodiments, wherein the at least two coils are not identical to each other and are at least different in size, model or structure.

24. The axial field rotational energy device,

A rotor including a rotating shaft and a magnet; And

A stator coaxial to the axis of rotation, wherein the stator comprises a plurality of stator segments and a plurality of electrical phases, each stator segment comprising a printed circuit board (PCB) having at least one PCB layer with a coil, each stator The segment contains only one electrical phase.

25. The axial field rotational energy device,

A rotor including a rotating shaft and a magnet; And

A stator coaxial with the rotor, wherein the stator comprises a plurality of stator segments coupled together about an axis, each stator segment comprising a printed circuit board (PCB) having a plurality of PCB layers each comprising a coil, The PCB layers are spaced apart from each other in the axial direction, each PCB has an even number of PCB layers, the PCB layer consists of a pair of layers, and each pair of layers is defined as two PCB layers electrically connected together; And

The coils in each PCB layer are coplanar, angularly and symmetrically spaced from each other with respect to the axis, and the coils in adjacent PCB layers are aligned circumferentially with each other to define a symmetrical stack of coils in the axial direction. do.

26. The axial field rotational energy device of any of these embodiments, wherein the stator comprises only one electrical phase and the coils are identical to each other.

27. The axial field rotational energy device of any of these embodiments, wherein the stator comprises a plurality of electrical phases.

28. The axial field rotation energy device of any of these embodiments, wherein each PCB layer is configured to provide only one electrical phase.

29. The axial field rotational energy device of any of these embodiments, wherein the coil on each PCB layer on each stator segment is configured to provide only one electrical phase.

30. The axial field rotational energy device of any of these embodiments, wherein the axial field rotational energy device constitutes a single electrical phase.

1. In the module for an axial field rotational energy device,

A housing having a coupling structure configured to mechanically couple the housing to a second housing of the second module and an electrical element configured to electrically couple the housing to the second housing;

A rotor rotatably mounted on the housing and including a shaft and a magnet; and

A stator mounted to the housing coaxially with the rotor, wherein the stator comprises a printed circuit board (PCB) having a PCB layer comprising a coil.

2. The module of any of these embodiments, wherein the rotor and stator are enclosed by the housing and located inside.

3. The rotor includes a plurality of rotors, the magnet includes a plurality of magnets, the stator includes a plurality of stators, each stator includes a plurality of PCB layers, and each PCB layer includes a plurality of coils. Including, the module of any one of these embodiments.

4. The module of any of these embodiments, wherein the module is configured to be directly connected to the frame and the module is configured to be connected indirectly to the second module.

5. The module of any one of these embodiments, wherein the housing includes sidewalls for orienting the stator in a desired angular direction with respect to the axis.

6. The module of any one of these embodiments, wherein the stator comprises a plurality of stators, and the sidewall comprises a plurality of sidewall segments angularly offsetting the plurality of stators in a desired angular orientation with respect to the axis.

7. Each side wall segment comprises a radial inner surface having a slot formed therein, the slot receiving and maintaining the desired angular orientation of the stator with respect to the axis, and the slots collectively at the gap gap between the stator and the rotor. The module of any of these embodiments, retaining the outer edge of the stator.

8. The stator is air-cooled and not water-cooled, the module of any one of these embodiments.

9. The PCB layer contains a plurality of PCB layers, each of which has a plurality of coils, each coil has only two terminals, each coil is continuous and uninterrupted between only two terminals, and each coil The module of any one of these embodiments, which is electrically coupled through other coils and vias.

10. The module of any of these embodiments, wherein the two coils are joined together to define a coil pair, and each coil pair is coupled with another coil pair through a different via.

11. Module of any of these embodiments, with each coil pair located on a different PCB layer.

12. The module of any one of these embodiments, wherein each coil couples with the other coil with only one via, and each coil pair with the other coil pair with only one other via.

13. The module of any of these embodiments, wherein the stator comprises a plurality of stator segments, each comprising a PCB.

14. The module of any of these embodiments, wherein the stator constitutes only one electrical phase.

15. The module of any of these embodiments, wherein the stator comprises a plurality of electrical phases.

16. In the module for an axial field rotational energy device,

A housing including a coupling structure configured to mechanically couple the housing to a second housing of the second module, and an electrical element configured to electrically couple the housing to the second housing;

A plurality of rotors rotatably installed in the housing, and the rotor includes a shaft and a magnet; And

The plurality of stators are installed in the housing coaxially with the rotor, each stator includes a printed circuit board PCB having a PCB layer including a coil, and the stators are electrically coupled together in the housing.

17. In the module for an axial field rotational energy device,

A housing having a coupling structure configured to mechanically couple the housing to a second housing of the second module, and an electrical element configured to electrically couple the housing to the second housing;

A rotor rotatably installed in the housing with respect to an axis, and each rotor comprises a magnet;

A stator mounted on the housing coaxially with the rotor, each stator comprising a printed circuit board (PCB) having a PCB layer, each PCB layer comprising a coil; And

The housing includes a plurality of sidewall segments for orienting the stator in a desired angular direction with respect to the axis, offsetting the stator angularly at the desired phase angle, the sidewall segments including a radial inner surface with a slot formed therein, the slot being the stator Maintaining each desired angular direction and axial spacing, the slots collectively retain the outer edge of the stator at the desired void spacing between the stator and the rotor.

18. The rotor and stator are located inside and surrounded by a housing, in addition:

The module of any one of these embodiments, wherein the frame, the module is configured to be directly coupled to the frame and the module is configured to be indirectly coupled to the second module.

19. The module of any one of these embodiments, wherein each coil has only two terminals, each coil is continuous and uninterrupted between the two terminals and each coil is electrically connected to the other coil through a via.

20. A module in any of these embodiments, wherein each coil is connected to the other coil by one via.

21. The module of any of these embodiments, wherein the two coils are coupled together to define a coil pair, each coil pair being electrically coupled to another coil pair with a different via.

22. The module includes a coil of each coil pair located on a different PCB layer; or

Each pair of coils coupled with another pair of coils with only one via; At least one module of these embodiments, comprising at least one of.

23. The module of any of these embodiments, wherein each stator comprises a plurality of stator segments, and each stator segment comprises a PCB.

24. A module in any of these embodiments, wherein each stator constitutes only one electrical phase.

25. The module of any of these embodiments, wherein each stator comprises a plurality of electrical phases.

26. A module for an axial field rotational energy device, comprising:

A housing with an axis;

A rotor rotatably installed in the housing with respect to the shaft, and each rotor includes a magnet;

A stator is installed in the housing coaxially to the rotor, each stator includes a printed circuit board PCB having a PCB layer including a coil, and each stator consists of a single electric phase,

The selected stators are angularly offset from each other with respect to the axis at the desired phase angle so that the module contains one or more electrical phases.

27. The module of any of these embodiments, wherein the housing comprises a sidewall having a plurality of sidewall segments.

28. Each side wall segment includes a slot on its inner surface, the side wall segment engages and orients the stator in the desired angular direction with respect to the axis, each stator angularly offset with respect to the other stator at the desired phase angle, and the stator The module of any one of these embodiments, wherein is seated in the slot of the sidewall segment and the slot collectively retains the outer edge of the stator at the desired void spacing between the stator and rotor.

29. The module of any of these embodiments, wherein each stator constitutes only one PCB.

30. The module of any of these embodiments, wherein the stator comprises two or more PCBs joined together to form each stator.

1. In the system,

A plurality of modules comprising an axial field rotational energy device, the modules are connected together for a desired power input or output, each module comprising:

A housing with an axis; Wherein the housing is mechanically coupled to at least one other module, and the housing is electrically coupled to the at least one other module;

A rotor rotatably mounted on the housing and each rotor includes a magnet; And

A stator comprising a printed circuit board (PCB), each having a PCB layer comprising a coil.

2. The system of any one of these embodiments, wherein the modules are identical to each other.

3. The system of any one of these embodiments, wherein at least two of the modules differ in at least one of the power output, the number of rotors, the number of magnets, the number of stators, the number of PCBs, the number of PCB layers, the number of coils, or the angular direction with respect to the axis. .

4. The system of any of these embodiments, wherein the modules are directly coupled to each other.

5. The system of any of these embodiments, wherein the modules are indirectly coupled to each other.

6. The system of any one of these embodiments, wherein each module includes a latch that mechanically holds the module, the latches being arranged symmetrically about the axis.

7. The system of any one of these embodiments, wherein one of the modules comprises a first module axially connected to another module, the first module being structurally different from the other module.

8. The system of any one of these embodiments, wherein the module is coaxial and mounted on keyed shafts that mechanically couple the module.

9. The system of either of these embodiments further comprises an enclosure, the modules being mounted and joined together within the enclosure.

10. The system of any one of these embodiments, wherein the enclosure comprises a plurality of enclosures each mechanically coupled to at least one other enclosure and electrically coupled to the at least one other enclosure.

11. The system of any one of these embodiments, wherein each stator consists of a single electrical phase, and a selected one of the stators is offset from each other at a desired electrical phase angle with respect to the axis.

12. The system of any of these embodiments, wherein each stator comprises a plurality of electrical phases.

13. The system of any one of these embodiments, wherein each module comprises a single electrical phase, and each module is angularly offset from one another at a desired electrical phase angle with respect to the axis.

14. The system of any of these embodiments, wherein each module includes a plurality of electrical phases, each module being angularly offset from each other at a desired electrical phase angle with respect to the axis.

15. The system of any of these embodiments, wherein the modules are angularly aligned with each other with respect to the axis, and all phase angles of the modules are also angularly aligned.

16. In the assembly,

Modules comprising an axial field rotational energy device-the modules are mechanically and electrically connected to each other for a desired power input or output, each module consisting of a single electrical phase;

Enclosure in which modules are mounted and joined;-Each module:

A housing having a shaft, mechanically coupled to at least one other module and electrically coupled to the at least one other module;

A rotor rotatably mounted to the housing, wherein the rotor comprises a magnet; And

Stator, each stator comprising a printed circuit board (PCB) having a PCB layer, each PCB layer comprising a coil.

17. An assembly in any of these embodiments, wherein the modules are identical to each other.

18. An assembly of any one of these embodiments, wherein at least two of the modules differ in at least one of the power output, the number of rotors, the number of magnets, the number of stators, the number of PCBs, the number of PCB layers, the number of coils, or the angular direction to the axis .

19. The assembly of any one of these embodiments, wherein the modules are directly coupled to each other.

20. The assembly of any one of these embodiments, wherein the modules are indirectly coupled to each other.

21. The system of any one of these embodiments, wherein each module includes a latch that mechanically holds the module, the latch being arranged symmetrically about an axis.

22. An assembly of any of these embodiments, wherein one of the modules comprises a first module axially connected to another module, the first module being structurally different from the other module.

23. The assembly of any of these embodiments, wherein the module is coaxial and mounted on keyed shafts that mechanically couple the module.

24. The enclosure comprises a plurality of enclosures, each having a coupling structure that mechanically couples the enclosure to at least one other enclosure, and an electrical element that electrically couples the enclosure to the at least one other enclosure. Assembly of any of the examples.

25. The assembly of any one of these embodiments, wherein the modules are angularly offset from each other at a desired electrical phase angle with respect to the axis.

26. In the assembly,

A plurality of modules comprising an axial field rotational energy device; -The modules can be connected identically and interchangeably for the desired power input or output, the assembly consisting of a generator or motor of a single electric phase;

An enclosure in which a module is mounted and coupled thereto; Each module:

A housing having a shaft, a coupling structure mechanically coupling the housing to at least one other module, and an electrical element electrically coupling the housing to at least one other module;

A plurality of rotors rotatably mounted in the housing,-the rotor comprises a magnet,

Each includes a printed circuit board (PCB) having a plurality of PCB layers, and each PCB layer includes a plurality of stators including a plurality of coils.

27. The enclosure comprises a plurality of enclosures, each having a coupling structure that mechanically couples the enclosure to at least one other enclosure, and an electrical element that electrically couples the enclosure to the at least one other enclosure. Assembly of any of the examples.

28. The assembly of any one of these embodiments, wherein the modules are angularly offset from each other at a desired electrical phase angle with respect to the axis.

29. A method of maintaining an axial field rotational energy device, the method comprising:

(a) Providing an enclosure having a plurality of modules, each module including a housing and a rotor rotatably mounted on the housing, the rotor includes a shaft and a magnet, and the stator is mounted on the housing coaxially with the rotor And the stator comprises a printed circuit board (PCB);

(b) mechanically and electrically coupling the modules;

(c) actuating the axial field rotational energy device;

(d) detecting a problem with the first module and stopping the operation of the axial field rotation energy device;

(e) opening the enclosure and disassembling the first module from the enclosure and other modules to which the first module is attached;

(f) installing a second module in the enclosure instead of the first module and attaching the second module to any other module to which the first module is attached; And

(g) reactivating the axial field rotational energy device; includes.

30. This way,

Detecting a problem with the first stator of the first module and deactivating the axial field rotational energy device;

Opening the first module and disassembling the first stator from the first module;

Installing a second stator in the first module in place of the first stator;

Then, the step of re-operating the axial field rotational energy device; further includes.

1. In the axial field rotational energy device,

housing;

A rotor mounted inside the housing and having a rotating shaft and a magnet;

A stator mounted inside the housing coaxially with the rotor, the stator including a printed circuit board (PCB) having a PCB layer with a coil; And

A sensor integrated within the housing, wherein the sensor is configured to monitor, detect or generate data relating to the operation of the axial field rotational energy device.

2. The axial field rotational energy device of at least one of these embodiments, wherein the operation data comprises at least one of power, temperature, rotational speed, rotor position or vibration data.

3. The axial field rotational energy device of any of these embodiments, wherein the sensor comprises at least one of a Hall effect sensor, an encoder, an optical sensor, a thermocouple, an accelerometer, a gyroscope or a vibration sensor.

4. The axial field rotational energy device is a motor;

The sensor is configured to provide information about the position of the rotor in the motor;

The axial field rotational energy device of any one of these embodiments, wherein the sensor is mounted in the housing.

5. The axial field rotational energy device of any of these embodiments, wherein the sensor comprises a wireless communication circuit.

6. The axial field rotation energy device of any of these embodiments, wherein the sensor is configured to transmit operation data of the axial field rotation energy device to an external device.

7. The axial field rotational energy device of any of these embodiments, wherein the sensor is integrated on a PCB.

8. The axial field rotational energy device of any one of these embodiments, wherein the sensor is built directly into the coil and configured to be electrically powered directly by the coil.

9. The axial field rotation energy device of any one of these embodiments, wherein the sensor is connected to the coil and configured to be powered through a separate electrical connection placed on or inside the PCB.

10. The axial field rotation energy device of any one of these embodiments, further comprising a secondary coil integrated with a PCB coupled to the sensor.

11. The axial field rotation energy device of any one of these embodiments, wherein the secondary coil is configured to supply power to the sensor by utilizing the magnetic flux generated during operation.

12. In the axial field rotational energy device,

housing;

A rotor installed inside the housing; Where the rotor includes a rotating shaft and a magnet,

A stator installed inside the housing coaxial to the rotor; Here, the stator includes a printed circuit board (PCB) having a PCB layer having a coil,

A control circuit mounted inside the housing; wherein the control circuit includes at least one of an input coupled to the coil and coupled to receive a current flowing through the coil or an output coupled to provide a current flowing through the coil.

13. The axial field rotational energy device of any of these embodiments, wherein the control circuit is integrated on the PCB.

14. In the axial field rotational energy device of any one of these embodiments,

The axial field rotational energy device is a generator; And

The control circuit includes an input coupled to receive the current flowing through the coil, and further includes an output coupled to generate an external power source.

15. In the axial field rotational energy device of any one of these embodiments,

The axial field rotation energy device is a motor; And

The control circuit includes an input coupled to receive an external power source, and further includes an output coupled to provide a current flowing through the coil.

16. In the axial field rotational energy device of any one of these embodiments, further comprising a sensor integrated inside the housing,

The sensor is configured to provide information about the position of the rotor in the motor; And

The sensor is installed in the housing.

17. In the axial field rotational energy device,

housing;

A rotor including a rotating shaft and a magnet and installed inside the housing;

A stator including a printed circuit board (PCB) having a PCB layer having a coil, and installed inside the housing coaxially to the rotor;

A sensor integrated on the PCB; And

And a secondary coil coupled to the sensor and disposed in or on the PCB.

18. In the axial field rotation energy device of any one of these embodiments, the sensor is configured to be supplied with power and connected to the coil through a separate electrical connection disposed on or inside the PCB;

The sensor is configured to transmit operation data of the axial field rotational energy device to an external device using a secondary coil.

19. In an axial field rotational energy device, the secondary coil is configured to provide power to the sensor using the magnetic flux generated during operation, and the sensor is otherwise not connected to the coil.

20. In the axial field rotational energy device,

The sensor includes at least one of a Hall effect sensor, an encoder, an optical sensor, a thermocouple, an accelerometer, a gyroscope, or a vibration sensor; And

The sensor includes a wireless communication circuit.

1. In the axial field rotational energy device,

A rotor including a rotating shaft and a plurality of magnets; Where each magnet extends in a radial direction with respect to its axis, said each magnet comprising a magnet radial edge,

A stator coaxial to the rotor; The stator comprises a plurality of PCB layers having each coil including a coil radial edge, and each of a plurality of coils,

When the radial edge portions of the magnet and coil are rotationally aligned about the axis, the magnet radial edge and the coil radial edge are not parallel but angularly skewed with respect to each other.

2. The axial field rotational energy device of any of these embodiments, wherein the angular skew is greater than or equal to about 0.1 degrees.

3. The axial field rotational energy device of any one of these embodiments, wherein the angular skew is at least about 1 degree.

4. The axial field rotational energy device of any of these embodiments, wherein the angular skew is not greater than about 25 degrees.

5. The axial field rotational energy device according to any of these embodiments, wherein the magnet radial edge and the coil radial edge are the leading or trailing radial edges of the magnet and coil, respectively.

6. The axial field rotational energy device of any one of these embodiments,

Here, each of the magnet radial edge and the coil radial edge is linear, and when the radial edge portions of the magnet and coil are rotationally aligned with respect to the axis, neither of the magnet radial edge and the coil radial edge are parallel.

7. The axial field rotational energy device of any one of these embodiments, wherein when the magnet and the radial edge portions of the coil are rotationally aligned, at least a portion of the magnet radial edge and the coil radial edge are parallel to each other.

8. The axial field rotational energy device of any of these embodiments, wherein the magnet radial edge and coil radial edge are not entirely linear.

9. In the axial field rotational energy device,

A rotor including a rotating shaft and a magnet, each magnet having a magnet radial edge; And

A stator coaxial with the rotor; wherein the stator includes a plurality of stator segments coupled together about an axis, each stator segment including a printed circuit board (PCB) having a PCB layer containing a coil, each The coil has a coil radial edge;

When the radial edge portions of the magnet and coil are rotationally aligned about the axis, the magnet radial edge and the coil radial edge are not parallel and are angled relative to each other.

10. The axial field rotational energy device of any of these embodiments, wherein the angular skew is about 0.1 degrees or more.

11. The axial field rotational energy device of any of these embodiments, wherein the angular skew is at least about 1 degree.

12. The axial field rotational energy device of any of these embodiments, wherein the angular skew is not greater than about 25 degrees.

13. The axial field rotational energy device of any one of these embodiments, wherein at least a portion of the magnet radial edge and the coil radial edge is a leading radial edge or a trailing radial edge of the magnet and coil, respectively.

14. The axial field of any one of these embodiments, wherein each of the magnet radial edge and the coil radial edge is linear, and when at least a portion of the magnet and coil is rotationally aligned, no portion of the magnet radial edge and the coil radial edge are parallel. Rotational energy device.

15. The axial field rotational energy device of any one of these embodiments, wherein when the magnet and at least a portion of the coil are rotationally aligned, the magnet radial edge and at least a portion of the coil radial edge are parallel to each other.

16. The axial field rotational energy device of any of these embodiments, wherein the magnet radial edge and coil radial edge are not completely linear.

17. A module for an axial field rotational energy device, comprising: a housing configured to mechanically couple the housing to a second housing of the second module and electrically couple the housing to the second housing;

A rotor rotatably mounted on the housing; -The rotor contains a shaft and a magnet, the magnet has a magnet radial edge,

A stator mounted on the housing coaxially with the rotor; wherein the stator comprises a printed circuit board (PCB) having a PCB layer with a coil, the coil has a coil radial edge,

When the radial edge portions of the magnet and coil are rotationally aligned about the axis, the magnet radial edge and at least the radial edge portions of the coil radial edge are not parallel but inclined at an angle to each other.

18. The axial field rotational energy device of any one of these embodiments, wherein each skew is at least about 0.1 degrees and less than about 25 degrees.

19. The axial field rotational energy device of any one of these embodiments, wherein the magnet radial edge and the coil radial edge are the leading or trailing radial edges of the magnet and coil, respectively.

20. Here, the magnet radial edge and the coil radial edge are linear, and when the radial edge portions of the magnet and coil are rotationally aligned, the axis of either of these embodiments is not parallel to either the magnet radial edge and the coil radial edge. Directional field rotation energy device.

1. In the axial field rotational energy device,

housing;

A rotor mounted inside the housing and having a rotating shaft and a magnet;

A stator mounted inside the housing coaxially with the rotor; wherein the stator includes a printed circuit board (PCB) having a PCB layer having an electrically conductive trace, and the trace is a radial trace extending in a radial direction with respect to the axis And a distal turn trace extending between the and the radial trace, the trace including a slit extending through at least a portion of the trace.

2. The axial field rotational energy device of any of these embodiments, wherein the slit is only a radial trace.

3. The axial field rotational energy device of any of these embodiments, wherein each slit is linear.

4. The axial field rotational energy device of any of these embodiments, wherein each slit is only linear and the slit does not contain a non-linear portion.

5. The axial field rotational energy device of any one of these embodiments, wherein the trace is tapered in a radial direction with respect to the axis.

6. The trace includes the outer width in a plane adjacent to the outer diameter of the PCB and perpendicular to the axis, the trace includes the inner diameter of the PCB and the inner width adjacent to the plane, and the outer width is greater than the inner width. One axial field rotation energy device.

7. The axial field rotational energy device of any one of these embodiments, wherein the trace includes inner and outer opposing edges and all of the inner and outer opposing edges are not parallel to each other.

8. The axial field rotational energy device of any of these embodiments, with only radial traces tapered.

9. The axial field rotational energy device of any of these embodiments, wherein the traces consist of inner and outer opposite edges parallel to each outer.

10. The axial field rotational energy device of any of these embodiments, wherein the end turn trace is tapered.

11.The axial field rotation of any of these embodiments, wherein the PCB layer includes the PCB layer surface area, and the traces on the PCB layer include the trace surface area in the range of at least about 75% to about 99% of the PCB layer surface area. Energy device.

12. The axial field rotational energy device,

housing;

A rotor mounted inside the housing and having a rotating shaft and a magnet; And

Including; a stator mounted inside the housing coaxially with the rotor,

The stator comprises a printed circuit board (PCB) having a PCB layer with coils, each coil contains a trace, at least some of the traces are tapered to opposite edges inside and outside that are not parallel to each other, and the traces are Includes the outer width in a plane adjacent to the outer diameter and perpendicular to the axis, the trace consists of the inner diameter of the PCB and the inner width adjacent the plane, the outer width being greater than the inner width.

13. The axial field rotational energy device of any one of these embodiments, wherein the coil includes a slit extending through at least a portion of the trace.

14. In the axial field rotational energy device of either of these embodiments, the trace comprises a radial trace extending radially about the axis and an end turn trace extending between the radial traces.

15. The axial field rotational energy device of any of these embodiments, wherein only the radial trace is tapered.

16. The axial field rotational energy device of any of these embodiments further comprises a slit only within the radial trace.

17. The axial field rotational energy device of any of these embodiments, wherein each slit is only linear and each slit has no non-linear portion.

18. The axial field rotational energy device,

housing;

A rotor having a rotating shaft and a magnet and installed in the housing; And

Includes; a stator installed inside the housing coaxially with the stator, wherein the stator includes a printed circuit board (PCB) having a PCB layer with a coil, each coil includes a trace, and at least some of the traces are tapered. , The trace includes a radial trace extending radially about the axis and an end turn trace extending between the radial traces, only the radial traces are tapered.

19. The axial field rotation energy device of any one of these embodiments, further comprising a linear slit only in the radial trace, the linear slit is only linear, and the linear slit does not contain a non-linear portion.

20. At least some of the tapered radial traces have inner and outer opposing edges that are not parallel to each other, the traces consist of an outer width adjacent to the outer diameter of the PCB and a plane perpendicular to the axis, and the traces are the inner diameter and the plane of the PCB. The axial field rotational energy device of any one of these embodiments, consisting of an inner width adjacent to and an outer width greater than the inner width.

1. In the axial field rotational energy device,

A housing having an axis having an axial direction;

A stator assembly mounted on the housing and including a plurality of stator panels stacked in an axial direction and a panel separated from each other; Here, each stator panel includes a respective printed circuit board (PCB) having a plurality of coils each electrically conductive and interconnected within each PCB, and each PCB is through any one of each of the plurality of coils. The flowing current is likewise configured to flow through all of each of the plurality of coils such that each stator panel is composed of a single electric phase; And

A rotor assembly including a plurality of rotors rotatably mounted in the housing at opposite axial ends of the stator assembly, wherein each rotor includes a magnet, and a stator panel adjacent in the axial direction No rotor is placed between them.

2. The device of any of these embodiments, wherein the stator panels are joined in a substantially axial abutting relationship.

3. The device of any of these embodiments, wherein the stator panels are mechanically coupled directly to each other in an axially abutting relationship.

4. The device of any of these embodiments, wherein the stator panel is arranged to rotate at a single angle relative to the axis.

5. The device of any of these embodiments, wherein the stator panels are electrically coupled together to form a single electrical circuit for the device.

6. The device of any of these embodiments, in which no axial spacers are arranged between the axially adjacent stator panels.

7. The arrangement of any one of these embodiments, wherein the coils extend in a generally radial direction with respect to the axis, each coil comprising an edge extending in the radial direction, the coil edges being substantially parallel to each other.

8. The device of any of these embodiments, wherein the stator assembly includes a plurality of electrical phases, and the stator panels are rotationally offset from each other about the axis at a desired angle.

9. The device of any of these embodiments, wherein the stator panel is configured not to be electrically coupled together to form a single electrical circuit for the device.

10. The device of any of these embodiments, wherein the stator assembly constitutes only three stator panels.

11. The device of any of these embodiments, wherein the rotor constitutes only two rotors.

12. In the device of any one of these embodiments,

Each spacer disposed between adjacent stator panels in the axial direction; And

It further comprises an axial spacer between the stator assembly and the rotor, wherein the axial spacer sets an axial clearance gap between the stator assembly and the rotor.

13. In the device of any of these embodiments, each PCB is composed of a PCB layer, each coil of each stator panel is formed by a single concentric electrically conductive trace on a single PCB layer of each PCB, and each The coils on the PCB layer are rotationally aligned about the axis with the coils on different layers of the PCB layer, each trace connected in series or parallel to the same PCB layer within each PCB and to other traces on a different PCB layer on each PCB. do.

14. In the axial field rotational energy device,

A housing having an axial axis;

A stator assembly including a plurality of single-phase stator panels stacked in the axial direction and a panel separated from each other, wherein the stator panel is mechanically fixedly coupled to the housing, and the stator panel is coupled in a substantially axial contact relationship , Each stator panel comprises a respective printed circuit board (PCB) having respective coils connected in series and electrically conductive within each PCB; And

Each PCB contains a PCB layer, each coil on each stator panel is formed by a single concentric electrically conductive trace on a single PCB layer of each PCB, and the coil of each PCB layer is on a different layer of the PCB layer. Rotationally aligned about the coil and axis, each trace is connected in series to the same PCB layer within each PCB and to another trace on a different PCB layer of each PCB, and

A rotor rotatably mounted in the housing at an axially opposite end of the stator assembly, wherein the rotor is mechanically coupled with a rotor spacer, each rotor includes a magnet, and between axially adjacent stator panels No rotor is placed.

15. The device of any of these embodiments, wherein the stator panels are mechanically coupled directly to each other in an axially abutting relationship.

16. The device of any of these embodiments, wherein the stator panels are rotationally aligned at a single angle with respect to the axis such that the stator panels are electrically connected together to form a single electrical circuit for the device.

17. The device of any of these embodiments, wherein no axial spacers are disposed between axially adjacent stator panels.

18. The apparatus of any one of these embodiments, wherein the coil extends in a generally radial direction with respect to the axis, each coil comprising an edge extending in a radial direction, and the coil edges are substantially parallel to each other. .

19. The stator assembly comprises a plurality of electrical phases, the stator panels being rotationally offset from each other at a desired angle with respect to the axis, the stator panels being configured not to be electrically coupled together to form a single electrical circuit for the device. Device.

20. The device of any of these embodiments, wherein the stator assembly comprises only three stator panels, the rotor comprises only two rotors, and the device comprises:

Each spacer disposed between adjacent stator panels in the axial direction; And

It further includes an axial spacer between the stator assembly and the rotor, wherein the axial spacer sets an axial gap gap between the stator assembly and the rotor.

1. In the axial field rotational energy device,

A housing having an axial axis;

A stator assembly mounted on the housing and including a plurality of stator panels stacked in an axial direction and a panel separated from each other; Here, each stator panel includes a respective printed circuit board (PCB) having a plurality of coils each electrically conductive and interconnected within each PCB, and each PCB is through any one of each of the plurality of coils. The flowing current is likewise configured to flow through all of each of the plurality of coils such that each stator panel is composed of a single electric phase; And

A rotor assembly including a plurality of rotors rotatably mounted in the housing at opposite axial ends of the stator assembly, wherein each rotor includes a magnet, and the magnets are preceding and following. A device comprising an edge, wherein the trailing edge of one magnet and the leading edge of an adjacent magnet are parallel to each other to define a consistent circumferential spacing about the axis between adjacent magnets.

2. The device of any of these embodiments, wherein each stator panel comprises two identical, C-shaped PCB segments that are electrically coupled together to form the respective stator panel.

3. The device of any one of these embodiments, wherein the stator panels are mechanically coupled to the housing collectively using fasteners in axial abutting relationship and in axial abutting relationship.

4. In any one of these embodiments, each stator panel is rotationally aligned with respect to the axis, the plurality of stator panels being (a) a single angle with respect to the axis to form a single electrical phase device, or , Or (b) a plurality of peripheral mounting holes configured to rotationally offset each other at a desired phase angle to form a multi-phase device.

5. The device of any of these embodiments, wherein each magnet is trapezoidal in shape.

6. The device of any of these embodiments, wherein each magnet comprises an inner radial edge parallel to the outer radial edge with respect to the axis.

7. In the device of any of these embodiments, the magnet comprises an even number of magnets, the magnets circumferentially adjacent to the axis contain opposite magnetic poles, and the opposite magnet in the opposite rotor is opposite. Device comprising the stimulation of.

8. In the device of any of these embodiments, each rotor includes a rotor hub, a magnetic backing is mounted on one of the axial directions of the rotor hub, and the magnet Mounted in the opposite axial direction, collectively the magnet defines an inner diameter of the magnet and an outer diameter of the magnet with respect to the axis, the magnetic backing has a backing inner diameter smaller than the inner diameter of the magnet, and the magnetic backing is the An apparatus having a backing outer diameter greater than the magnet outer diameter.

9. In the device of any of these embodiments, the rotor hub comprises a trapezoidal hole for each magnet, and the magnet is attached to the rotor hub only by magnetic attraction to the magnetic backing. Set device.

10. The device of any of these embodiments, wherein the backing outer diameter is flush with the outer perimeter of the rotor hub.

11. In the device of any of these embodiments, each stator panel comprises a plurality of cores comprising a magnetic material, each core being located at the center of each coil of the stator panel, the core from the coil. Device, electrically insulated.

12. The apparatus of any one of these embodiments, wherein the core comprises an axial surface that is flush with the axial surface of the stator panel.

13. The apparatus of any one of these embodiments, wherein the center of each coil comprises a volume located within an innermost trace of each coil.

14. The apparatus of any one of these embodiments, wherein the volume is formed during manufacture of the PCB such that a core is included during manufacture of the PCB.

15. The device of any one of these embodiments, wherein the volume is removed from the PCB after the PCB is manufactured so that the core is added to the PCB after manufacturing the PCB.

16. The device of any of these embodiments, wherein the housing comprises housing shells joined together, each housing shell each comprising an internal perimeter with an axial shelf formed therein. Wherein the stator assembly is mechanically coupled to at least one of the axial shelves; And

Wherein the stator panel comprises an outer peripheral edge in contact with the radially inner surface of the housing shell at the inner periphery.

17. The apparatus of any one of these embodiments, wherein the stator assembly comprises three stator panels, each configured to operate with a respective electrical phase, and configured to operate with a plurality of electrical phases together.

18. The device of any one of these embodiments, further comprising a control circuit integrated within the housing, the control circuit of the stator panel to facilitate retention of a factor of the device. An apparatus comprising a circular, donut-shaped shape complementary to the shape.

19. In the axial field rotational energy device,

A housing having an axial axis;

A stator assembly mounted on the housing and including a plurality of stator panels stacked in an axial direction and a panel separated from each other; Here, each stator panel includes a respective printed circuit board (PCB) having a plurality of coils each electrically conductive and interconnected within each PCB, and each PCB is through any one of each of the plurality of coils. The flowing current is likewise configured to flow through all of each of the plurality of coils such that each stator panel is composed of a single electric phase; And

A rotor assembly including a plurality of rotors rotatably mounted in the housing at an opposite axial end of the stator assembly, wherein each rotor includes a magnet, and the magnet is a preceding and A trailing edge, wherein the trailing edge of one magnet and the leading edge of adjacent magnets are parallel to each other to define a consistent circumferential spacing about the axis between adjacent magnets, and

Each rotor includes a rotor hub, magnetic backing is mounted on one axial direction of the rotor hub, and the magnet is mounted on an axial direction opposite to the rotor hub, and collectively the magnets Define a magnet inner diameter and a magnet outer diameter for the axis, the magnetic backing has a backing inner diameter smaller than the magnet inner diameter, and the magnetic backing has a backing outer diameter greater than the magnet outer diameter. , Device.

20. In the axial field rotational energy device,

A housing having an axial axis;

A stator assembly mounted on the housing and including a plurality of stator panels stacked in an axial direction and a panel separated from each other, wherein each stator panel is electrically conductive and interconnected in each PCB Each of the printed circuit boards (PCBs) having coils of are included, and each of the PCBs is configured such that a current flowing through any one of the plurality of coils likewise flows through all of the plurality of coils, and each stator The panel consists of a single electric phase; And

Each stator panel includes a plurality of cores comprising a magnetic material, each core being located at the center of each coil of the stator panel, the core being electrically insulated from the coil, and

A rotor assembly including a plurality of rotors rotatably mounted in the housing at an opposite axial end of the stator assembly, wherein each rotor includes a magnet, and the magnet is a preceding and An apparatus comprising a trailing edge, wherein the trailing edge of one magnet and the leading edge of adjacent magnets are parallel to each other to define a consistent circumferential spacing about the axis between adjacent magnets.

This recorded description uses examples to disclose embodiments including the best mode and also to enable any person skilled in the art to make and use the present invention. The patentable range is defined by the claims, and may include other examples that occur to those skilled in the art. Other such examples are intended to be within the scope of the claim if it has structural elements that do not differ from the literal language of the claim or includes equivalent structural elements that do not differ materially from the literal language of the claim.

Note that not all activities described above in the general description or example are required, some of the specific activities may not be required, and one or more additional activities may be performed in addition to those described. Also, the order in which the activities are listed is not necessarily the order in which they are performed.

In the foregoing specification, concepts have been described with reference to specific embodiments. However, those skilled in the art appreciate that various modifications and changes may be made without departing from the scope of the invention as set forth in the following claims. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a limiting sense, and all such modifications are intended to be included within the scope of the present invention.

It may be advantageous to provide definitions of specific words and phrases used throughout this patent document. The term “communicate” and its derivatives include both direct and indirect communication. The terms “include”, “comprise” and derivatives thereof are meant to be included without limitation. The term "or" is inclusive and/or is. “associated with” and its derivatives include, include, be included within, interconnect with, contain, be contained within, connect to or with, Couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with ), have, have a property of, have a relationship to or with, etc. When used with an item list, the phrase “at least one” means that different combinations of one or more of the items listed may be used and only one item in the list may be required. For example, “one or more of A, B, and C” includes combinations of A, B, C, A and B, A and C, B and C, and A and B and C.

Also, the use of "a" or "an" is used to describe the elements and components described herein. This is done for convenience only and to give a general meaning to the scope of the invention. This description should be read to include one or at least one, and the singular includes the plural unless it is clear otherwise.

Printed circuit boards (PCBs) are also known as printed wiring boards (PWBs) because such boards, as manufactured, typically contain wiring in one or more layers but not actual circuit elements. These circuit elements are then attached to such boards. As used here, there is no distinction between PCB and PWB. As used herein, the coil of the PCB is an electrically conductive coil. As used herein, a component or object “integrated with” a structure may be disposed on or within a structure. These components or objects can be mounted, attached or added to the structure after the structure itself is manufactured, and the component or object can be built into the structure or manufactured together with the structure.

Some embodiments described herein use one via to couple two coils together. In other embodiments, multiple vias may be provided instead of a single via to couple these coils together.

The description in this application is not to be construed as implying that any particular element, step or function is an essential or important element that should be included in the claims. The scope of the patented subject matter is defined only by the permitted claims. Moreover, with respect to the 35 USC§112(f) attached claim or claim element, unless the exact word “means for” or “step for” is explicitly used in a particular claim, then the function is followed. Followed by a nozzle to identify the. "Mechanism", "module", "device", "unit", "component", "element", "member", "apparatus", "machine" The use of terms such as, but not limited to, "system", "processor" or "controller" refers to structures known to those skilled in the art that are further modified or enhanced by the features of the claims themselves. It is understood and intended to be, and is not intended to invoke 35 USC § 112(f).

Benefits, other advantages and solutions to problems have been described above with respect to specific embodiments. However, benefits, advantages, solutions and benefits to problems, advantages, or any function that could cause or make a solution more prominent is an important, essential function of some or all arguments. Is not interpreted as.

After reading the specification, skilled artisans will understand that, for clarity, in the context of separate embodiments, certain features described herein may be provided in combination in a single embodiment. Conversely, for the sake of brevity, the various features described in the context of a single embodiment may also be provided individually or in any sub-combination. Also, references to values specified in a range include all values within that range.

Claims (15)

In the axial field rotational energy device,
A housing having an axial axis;
A stator assembly mounted on the housing and including a plurality of stator panels stacked in an axial direction and a panel separated from each other; Here, each stator panel includes a respective printed circuit board (PCB) having a plurality of coils each electrically conductive and interconnected within each PCB, and each PCB is through any one of each of the plurality of coils. The flowing current is likewise configured to flow through all of each of the plurality of coils such that each stator panel is composed of a single electric phase; And
A rotor assembly including a plurality of rotors rotatably mounted in the housing at opposite axial ends of the stator assembly, wherein each rotor includes a magnet, and the magnets are preceding and following. An edge, wherein the trailing edge of one magnet and the leading edge of adjacent magnets are parallel to each other to define a consistent circumferential spacing about the axis between adjacent magnets.
Device. The apparatus of claim 1, wherein each stator panel comprises two identical, C-shaped PCB segments that are electrically coupled together to form the respective stator panel. The apparatus of claim 1, wherein the stator panels are mechanically coupled to the housing collectively using fasteners in an axial abutting relationship and in an axial abutting relationship. The method of claim 1, wherein each stator panel is rotationally aligned with respect to the axis such that the plurality of stator panels are (a) a single angle with respect to the axis to form a single electric phase device, or (b) a multi-phase A device comprising a plurality of peripheral mounting holes configured to rotationally offset each other at a desired image angle to form the device. The apparatus of claim 1, wherein the magnet comprises an even number of magnets, the magnets circumferentially adjacent to the axis comprise opposite magnetic poles, and the opposite magnets in the opposing rotor comprise opposite magnetic poles. . The method of claim 1, wherein each rotor includes a rotor hub, a magnetic backing is mounted on one axial direction of the rotor hub, and the magnet is mounted on an axial direction opposite to the rotor hub, Collectively, the magnet defines a magnet inner diameter and a magnet outer diameter with respect to the shaft, the magnetic backing has a backing inner diameter smaller than the magnet inner diameter, and the magnetic backing has a backing outer diameter larger than the magnet outer diameter ( backing outer diameter). 7. The apparatus of claim 6, wherein the rotor hub comprises a trapezoidal hole for each magnet, the magnet being secured to the rotor hub only by magnetic attraction to the magnetic backing. The apparatus of claim 1, wherein each stator panel comprises a plurality of cores comprising a magnetic material, each core being located at the center of each coil of the stator panel, the core being electrically insulated from the coil. 9. The apparatus of claim 8, wherein the core comprises an axial surface substantially flush with the axial surface of the stator panel. 9. The apparatus of claim 8, wherein the center of each coil comprises a volume located within an innermost trace of each coil. 11. The apparatus of claim 10, wherein the volume is formed during manufacture of the PCB to contain a core during manufacture of the PCB. 11. The apparatus of claim 10, wherein the volume is removed from the PCB after the PCB is manufactured so that the core is added to the PCB after manufacturing the PCB. The method of claim 1, wherein the housing comprises housing shells joined together, each housing shell each comprising an internal perimeter with an axial shelf formed therein, and the stator assembly comprises the Mechanically coupled to at least one of the axial lathes; And
Wherein the stator panel comprises an outer peripheral edge in contact with the radially inner surface of the housing shell at the inner periphery. The apparatus of claim 1, wherein the stator assembly comprises three stator panels, each configured to operate with a respective electrical phase, and configured to operate with a plurality of electrical phases together. The method of claim 1, further comprising a control circuit integrated within the housing, wherein the control circuit is circular, complementary to the shape of the stator panel to facilitate retention of a factor of the device. An apparatus comprising a donut-shaped shape.

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