Abstract

An axial field rotary energy device can include a housing having an axis. A stator assembly is mounted to the housing and has stator panels that are axially-stacked and discrete panels from each other. Each stator panel includes a respective printed circuit board (PCB) having respective coils that are electrically conductive and interconnected within the respective PCB. In addition, a rotor assembly including rotors is rotatably mounted within the housing on opposite axial ends of the stator assembly. The rotors can be mechanically coupled together. Each rotor can include magnets having leading and trailing edges. The trailing edge of one magnet and the leading edge of an adjacent magnet can be parallel to each other to define a consistent circumferential spacing, relative to the axis, between adjacent ones of the magnets.

IPC Classes  ?

• H02K 16/02 - Machines with one stator and two rotors
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 1/2798 - Rotors axially facing stators the rotor consisting of two or more circumferentially positioned magnets where both axial sides of the stator face a rotor
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 5/04 - Casings or enclosures characterised by the shape, form or construction thereof
• H02K 11/30 - Structural association with control circuits or drive circuits
• H02K 16/00 - Machines with more than one rotor or stator
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 5/173 - Means for supporting bearings, e.g. insulating supports or means for fitting bearings in the bearing-shields using bearings with rolling contact, e.g. ball bearings

Abstract

An axial field rotary energy device can include a rotor having an axis of rotation and a printed circuit board (PCB) stator having PCB panels. Each PCB panel has conductive layers, each conductive layer has coils, and each coil has conductive traces. A radial portion of the conductive traces are arranged to form spaces so vias coupled to one phase do not intersect coils from another phase. The PCB stator can have a contoured outer ring that is a uniform distance from an inner edge thereof to the outer edges of the coils.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 1/2786 - Outer rotors
• H02K 9/22 - Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
• H02K 15/02 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
• H02K 15/0407 - Manufacturing of windings by etching, printing or stamping the complete coils

Abstract

An axial field rotary energy device can include a rotor comprising an axis of rotation and a magnet. In addition, a stator can be coaxial with the rotor. The stator can include a plurality of stator segments that are coupled together about the axis. Each stator segment can include a printed circuit board (PCB) having a PCB layer comprising a coil. Each stator segment also can include only one electrical phase. The stator itself can include one or more electrical phases.

IPC Classes  ?

• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 1/276 - Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
• H02K 1/2795 - Rotors axially facing stators the rotor consisting of two or more circumferentially positioned magnets
• H02K 1/32 - Rotating parts of the magnetic circuit with channels or ducts for flow of cooling medium
• H02K 3/12 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 3/47 - Air-gap windings, i.e. iron-free windings
• H02K 3/52 - Fastening salient pole windings or connections thereto
• H02K 9/12 - Arrangements for cooling or ventilating by gaseous cooling medium flowing in closed circuit, a part of which is external to the machine casing wherein the cooling medium circulates freely within the casing
• H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
• H02K 16/00 - Machines with more than one rotor or stator
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 35/02 - Generators with reciprocating, oscillating or vibrating coil system, magnet, armature or other part of the magnetic circuit with moving magnets and stationary coil systems
• H02P 31/00 - Arrangements for regulating or controlling electric motors not provided for in groups , or

Abstract

A system has an axial field rotary energy device with a housing, an axis and a rotor with a shaft, bearings, rotor disks and permanent magnets. A printed circuit board (PCB) stator is between the rotor disks to define an air gap on each side thereof. A variable frequency drive (VFD) assembly has a VFD housing and first pads coupled to inductors to facilitate heat removal from the inductors. A concave cradle is coupled to a ferromagnetic core and has a same contour as an outer surface of the ferromagnetic core. A second pad is coupled to a rectifier module. A third pad is coupled to switching devices and has pins to align the switching devices with the third pad. Standoffs are coupled to the VFD housing to support a first printed circuit board assembly (PCBA). A second PCBA is mounted to a shield plate above the first PCBA.

IPC Classes  ?

• H02K 5/06 - Cast metal casings
• H02K 5/02 - Casings or enclosures characterised by the material thereof
• H02K 11/00 - Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
• H02K 11/33 - Drive circuits, e.g. power electronics

Abstract

A printed circuit board (PCB) has a dielectric substrate of fiber-reinforced polymer with opposite sides. Each side has channels formed by molding or machining the dielectric substrate. Conductive wires are inserted into the channels to define conductive traces.

IPC Classes  ?

• H05K 1/02 - Printed circuits Details
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H05K 1/03 - Use of materials for the substrate
• H05K 3/18 - Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern using precipitation techniques to apply the conductive material

Abstract

A system can include an axial field rotary energy device with an axis of rotation and a rotor coaxial with the axis and having a shaft, bearings, rotor disks that are coaxial and permanent magnets on each rotor disk. A printed circuit board (PCB) stator is located between the rotor disks to define an air gap on each side of the PCB stator. An enclosure has two enclosure sections with an inspection port. Bearing caps and bearings are mounted to the rotor. A variable frequency drive (VFD) assembly is coupled to the axial field rotary energy device. The VFD has a flexible conduit that extends between the VFD housing and the axial field rotary energy device. The flexible conduit can adapt to different sizes of axial field rotary energy devices.

IPC Classes  ?

• H02K 11/33 - Drive circuits, e.g. power electronics
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 5/10 - Casings or enclosures characterised by the shape, form or construction thereof with arrangements for protection from ingress, e.g. of water or fingers
• H02K 5/173 - Means for supporting bearings, e.g. insulating supports or means for fitting bearings in the bearing-shields using bearings with rolling contact, e.g. ball bearings
• H02K 7/08 - Structural association with bearings
• H02K 9/06 - Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium with fans or impellers driven by the machine shaft
• H02K 9/22 - Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
• H02K 11/40 - Structural association with grounding devices
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Abstract

An axial field rotary energy device includes housing sections, each with a ferromagnetic core having teeth. A printed circuit board (PCB) stator assembly is mechanically and thermally coupled to each housing section and has stator windows through which the teeth protrude. An external circumferential channel directs a flow of a liquid coolant. A first lobe is aligned with an adjacent first lobe on an adjacent housing section. The first lobes form a manifold to distribute the liquid coolant to the housing sections. A second lobe is aligned with an adjacent second lobe on the adjacent housing section. The second lobes contain conductors for electrical connections of the PCB stator assemblies. The device also has an air gap between each facing pair of the ferromagnetic cores. A rotor with a rotor disk is axially positioned in a center of each respective air gap and has magnets.

IPC Classes  ?

• H02K 11/33 - Drive circuits, e.g. power electronics
• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 1/2793 - Rotors axially facing stators
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 5/20 - Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium
• H02K 9/19 - Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil
• H02K 9/22 - Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Abstract

An axial field rotary energy device includes housing sections, each with a ferromagnetic core having teeth. A printed circuit board (PCB) stator assembly is mechanically and thermally coupled to each housing section and has stator windows through which the teeth protrude. An external circumferential channel directs a flow of a liquid coolant. A first lobe is aligned with an adjacent first lobe on an adjacent housing section. The first lobes form a manifold to distribute the liquid coolant to the housing sections. A second lobe is aligned with an adjacent second lobe on the adjacent housing section. The second lobes contain conductors for electrical connections of the PCB stator assemblies. The device also has an air gap between each facing pair of the ferromagnetic cores. A rotor with a rotor disk is axially positioned in a center of each respective air gap and has magnets.

IPC Classes  ?

• H02K 16/04 - Machines with one rotor and two stators
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 9/19 - Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil
• H02K 5/20 - Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium

Abstract

An axial field rotary energy device can include a rotor comprising an axis of rotation and a magnet. In addition, a stator can be coaxial with the rotor. The stator can include a plurality of stator segments that are coupled together about the axis. Each stator segment can include a printed circuit board (PCB) having a PCB layer comprising a coil. Each stator segment also can include only one electrical phase. The stator itself can include one or more electrical phases.

IPC Classes  ?

• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 1/276 - Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
• H02K 1/2795 - Rotors axially facing stators the rotor consisting of two or more circumferentially positioned magnets
• H02K 1/32 - Rotating parts of the magnetic circuit with channels or ducts for flow of cooling medium
• H02K 3/12 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 3/47 - Air-gap windings, i.e. iron-free windings
• H02K 3/52 - Fastening salient pole windings or connections thereto
• H02K 9/12 - Arrangements for cooling or ventilating by gaseous cooling medium flowing in closed circuit, a part of which is external to the machine casing wherein the cooling medium circulates freely within the casing
• H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
• H02K 16/00 - Machines with more than one rotor or stator
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 35/02 - Generators with reciprocating, oscillating or vibrating coil system, magnet, armature or other part of the magnetic circuit with moving magnets and stationary coil systems
• H02P 31/00 - Arrangements for regulating or controlling electric motors not provided for in groups , or

Abstract

A system has an axial field rotary energy device with an axis, a printed circuit board (PCB) stator and a rotor with a rotor shaft and rotor disks having respective permanent magnets (PM). The rotor rotates about the axis relative to the PCB stator. A variable frequency drive (VFD) has VFD components coupled to the axial field rotary energy device. A device enclosure contains the axial field rotary energy device. A VFD enclosure contains the VFD, and the device and VFD enclosures are axially aligned and coupled to each other. A cooling system is integrated within the device and VFD enclosures and cools the axial field rotary energy device and the VFD. The cooling system has a cooling fan located axially outboard of the device and VFD enclosures. The cooling fan circulates an air flow radially and axially relative to the device and VFD enclosures.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 1/2795 - Rotors axially facing stators the rotor consisting of two or more circumferentially positioned magnets
• H02K 5/18 - Casings or enclosures characterised by the shape, form or construction thereof with ribs or fins for improving heat transfer
• H02K 5/20 - Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium
• H02K 9/06 - Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium with fans or impellers driven by the machine shaft
• H02K 11/33 - Drive circuits, e.g. power electronics
• H02K 16/02 - Machines with one stator and two rotors
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02P 27/06 - Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage using DC to AC converters or inverters

Abstract

A system has an axial field rotary energy device with a housing, an axis and a rotor with a shaft, bearings, rotor disks and permanent magnets. A printed circuit board (PCB) stator is between the rotor disks to define an air gap on each side thereof. A variable frequency drive (VFD) assembly has a VFD housing and first pads coupled to inductors to facilitate heat removal from the inductors. A concave cradle is coupled to a ferromagnetic core and has a same contour as an outer surface of the ferromagnetic core. A second pad is coupled to a rectifier module. A third pad is coupled to switching devices and has pins to align the switching devices with the third pad. Standoffs are coupled to the VFD housing to support a first printed circuit board assembly (PCBA). A second PCBA is mounted to a shield plate above the first PCBA.

IPC Classes  ?

• H02K 5/06 - Cast metal casings
• H02K 5/02 - Casings or enclosures characterised by the material thereof
• H02K 11/00 - Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
• H02K 11/33 - Drive circuits, e.g. power electronics

Abstract

An axial field rotary energy device can include a rotor having an axis of rotation and a printed circuit board (PCB) stator having PCB panels. Each PCB panel has conductive layers, each conductive layer has coils, and each coil has radial conductors and end turn conductors. The PCB stator also has conductive pads coupled to a temperature sensor. Each conductive pad is connected to a terminal through a respective conductive trace. The conductive pads are axially aligned or located directly adjacent to respective end turn conductors in a conductive layer that is separated from the end turn conductors by an insulation layer.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors

Abstract

An axial field rotary energy device can include a rotor having an axis of rotation and a printed circuit board (PCB) stator having PCB panels. Each PCB panel has conductive layers, each conductive layer has coils, and each coil has radial conductors and end turn conductors. The PCB stator also has conductive pads coupled to a temperature sensor. Each conductive pad is connected to a terminal through a respective conductive trace. The conductive pads are axially aligned or located directly adjacent to respective end turn conductors in a conductive layer that is separated from the end turn conductors by an insulation layer.

IPC Classes  ?

• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 3/28 - Layout of windings or of connections between windings

Abstract

A system can include an axial field rotary energy device with an axis of rotation and a rotor coaxial with the axis and having a shaft, bearings, rotor disks that are coaxial and permanent magnets on each rotor disk. A printed circuit board (PCB) stator is located between the rotor disks to define an air gap on each side of the PCB stator. An enclosure has two enclosure sections with an inspection port. Bearing caps and bearings are mounted to the rotor. A variable frequency drive (VFD) assembly is coupled to the axial field rotary energy device. The VFD has a flexible conduit that extends between the VFD housing and the axial field rotary energy device. The flexible conduit can adapt to different sizes of axial field rotary energy devices.

IPC Classes  ?

• H02K 11/33 - Drive circuits, e.g. power electronics
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 5/10 - Casings or enclosures characterised by the shape, form or construction thereof with arrangements for protection from ingress, e.g. of water or fingers
• H02K 5/173 - Means for supporting bearings, e.g. insulating supports or means for fitting bearings in the bearing-shields using bearings with rolling contact, e.g. ball bearings
• H02K 7/08 - Structural association with bearings
• H02K 9/06 - Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium with fans or impellers driven by the machine shaft
• H02K 9/22 - Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
• H02K 11/40 - Structural association with grounding devices
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Abstract

An axial field rotary energy device or system includes an axis, a PCB stator and rotors having respective permanent magnets. The rotors rotate about the axis relative to the PCB stator. A variable frequency drive (VFD) having VFD components are coupled to the axial field rotary energy device. An enclosure contains the axial field rotary energy device and the VFD, such that the axial field rotary device and the VFD are integrated together within the enclosure. In addition, a cooling system is integrated with the enclosure to cool the axial field rotary energy device and the VFD.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 1/2795 - Rotors axially facing stators the rotor consisting of two or more circumferentially positioned magnets
• H02K 5/18 - Casings or enclosures characterised by the shape, form or construction thereof with ribs or fins for improving heat transfer
• H02K 5/20 - Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium
• H02K 9/06 - Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium with fans or impellers driven by the machine shaft
• H02K 11/33 - Drive circuits, e.g. power electronics
• H02K 16/02 - Machines with one stator and two rotors
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02P 27/06 - Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage using DC to AC converters or inverters

Abstract

An axial field rotary energy device has a PCB stator panel assembly between rotors with an axis of rotation. Each rotor has a magnet. The PCB stator panel assembly includes PCB panels. Each PCB panel can have layers, and each layer can have conductive coils. The PCB stator panel assembly can have a thermally conductive layer that extends from an inner diameter portion to an outer diameter portion thereof.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H01F 17/00 - Fixed inductances of the signal type
• H01F 27/22 - Cooling by heat conduction through solid or powdered fillings
• H01F 27/28 - CoilsWindingsConductive connections
• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 9/22 - Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
• H02K 11/26 - Devices for sensing voltage, or actuated thereby, e.g. overvoltage protection devices
• H02K 11/30 - Structural association with control circuits or drive circuits
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H05K 1/02 - Printed circuits Details
• H05K 1/11 - Printed elements for providing electric connections to or between printed circuits
• H05K 1/16 - Printed circuits incorporating printed electric components, e.g. printed resistor, capacitor, inductor

Abstract

A printed circuit board (PCB) has a tridimensional (3D) dielectric substrate having opposite sides and made of fiber-reinforced polymer. Each side comprises channels and pockets formed by machining a dielectric laminate, and the channels and pockets define a layout for conductive traces and pads of the PCB. The channels and pockets in a same side of the 3D dielectric substrate have a uniform depth. Side walls of the channels and pockets have a draft angle in a range of greater than 0 degrees to about 5 degrees. The conductive traces and pads are formed into the channels and pockets by electrolytic metallization. In addition, the outer surface of conductive traces and pads are flush with the sides of the 3D dielectric substrate.

IPC Classes  ?

• H05K 1/02 - Printed circuits Details
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H05K 1/03 - Use of materials for the substrate
• H05K 3/18 - Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern using precipitation techniques to apply the conductive material

Abstract

A printed circuit board (PCB) has a tridimensional (3D) dielectric substrate having opposite sides and made of fiber-reinforced polymer. Each side comprises channels and pockets formed by molding or machining a dielectric laminate, and the channels and pockets define a layout for conductive traces and pads of the PCB. The channels and pockets in a same side of the 3D dielectric substrate have a uniform depth. Side walls of the channels and pockets have a draft angle in a range of at least about 5 degrees to at least about 15 degrees.

IPC Classes  ?

• H05K 1/02 - Printed circuits Details
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H05K 1/03 - Use of materials for the substrate
• H05K 3/18 - Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern using precipitation techniques to apply the conductive material

Abstract

A method for making a printed circuit board (PCB) with a tridimensional (3D) dielectric substrate having opposite sides and made of fiber-reinforced polymer. Each side comprises channels and pockets formed by molding or machining a dielectric laminate, and the channels and pockets define a layout for conductive traces and pads of the PCB. The channels and pockets in a same side of the 3D dielectric substrate have a uniform depth. Side walls of the channels and pockets have a draft angle in a range of at least about 5 degrees to at least about 15 degrees.

IPC Classes  ?

• H05K 3/10 - Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
• C25D 5/02 - Electroplating of selected surface areas
• C25D 5/56 - Electroplating of non-metallic surfaces of plastics
• C25D 7/00 - Electroplating characterised by the article coated
• H02K 15/02 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
• H02K 15/08 - Forming windings by laying conductors into or around core parts

Abstract

A method of manufacturing a printed circuit board (PCB) includes forming a tridimensional (3D) dielectric substrate on a fiber-reinforced polymer with opposite sides; forming each side with channels and pockets by molding dielectric laminate, and the channels and pockets define a layout for conductive traces and pads of the PCB; forming the channels and pockets in a same side of the 3D dielectric substrate at a uniform depth; forming side walls of the channels and pockets of the 3D dielectric substrate with a draft angle in a range of greater than 0 degrees to about 5 degrees; depositing by electrolytic metallization the conductive traces and pads into the channels and pockets of the 3D dielectric substrate; and the outer surface of those conductive traces and pads are flush with the sides of the 3D dielectric substrate.

IPC Classes  ?

• H05K 3/00 - Apparatus or processes for manufacturing printed circuits
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H05K 3/10 - Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
• H05K 1/16 - Printed circuits incorporating printed electric components, e.g. printed resistor, capacitor, inductor
• H05K 3/46 - Manufacturing multi-layer circuits

Abstract

A method for making a printed circuit board (PCB) with a tridimensional (3D) dielectric substrate having opposite sides and made of fiber-reinforced polymer. Each side comprises channels and pockets formed by molding or machining a dielectric laminate, and the channels and pockets define a layout for conductive traces and pads of the PCB. The channels and pockets in a same side of the 3D dielectric substrate have a uniform depth. Side walls of the channels and pockets have a draft angle in a range of at least about 5 degrees to at least about 15 degrees.

IPC Classes  ?

• H05K 3/10 - Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
• H05K 3/18 - Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern using precipitation techniques to apply the conductive material
• H05K 1/02 - Printed circuits Details
• H05K 1/09 - Use of materials for the metallic pattern

Abstract

A printed circuit board (PCB) has a tridimensional (3D) dielectric substrate 1200 having opposite sides 1201a, 1201b and made of fiber-reinforced polymer. Each side comprises channels and pockets 1202, 1203 formed by molding a dielectric laminate, and the channels and pockets define a layout for conductive traces and pads of the PCB. The channels and pockets in a same side of the 3D dielectric substrate have a uniform depth or non-uniform depths. Side walls of the channels and pockets have a draft angle in a range of greater than 0 degrees to about 5 degrees. The conductive traces and pads are formed into the channels and pockets 1200, 1203 by electrolytic metallization. In addition, the outer surface of conductive traces and pads are flush with the sides of the 3D dielectric substrate.

IPC Classes  ?

• H05K 3/00 - Apparatus or processes for manufacturing printed circuits
• H05K 3/10 - Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
• H05K 1/02 - Printed circuits Details
• H05K 1/16 - Printed circuits incorporating printed electric components, e.g. printed resistor, capacitor, inductor
• H05K 3/46 - Manufacturing multi-layer circuits

Abstract

A printed circuit board (PCB) has a tridimensional (3D) dielectric substrate having opposite sides and made of fiber-reinforced polymer. Each side comprises channels and pockets formed by molding or machining a dielectric laminate, and the channels and pockets define a layout for conductive traces and pads of the PCB. The channels and pockets in a same side of the 3D dielectric substrate have a uniform depth. Side walls of the channels and pockets have a draft angle in a range of at least about 5 degrees to at least about 15 degrees.

IPC Classes  ?

• H05K 1/02 - Printed circuits Details
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H05K 1/03 - Use of materials for the substrate
• H05K 3/18 - Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern using precipitation techniques to apply the conductive material

Abstract

A device has a housing and a rotor with an axis and a rotor disk with a magnet. A cooling plate is coupled to the housing. The cooling plate includes a channel connected to an inlet and an outlet to convey a liquid coolant. A stator is coaxial with the rotor and includes a printed circuit board with conductive layers laminated together with layers of an insulating material. Each conductive layer has coils that can carry electrical current when connected to an external voltage source. The stator is mechanically coupled to the housing, so the stator reacts to torque produced by the device. A ferromagnetic yoke is mechanically and thermally coupled to the stator and to the cooling plate to provide a path for magnetic flux produced by the magnet and a path to conduct heat generated by the stator from the stator to the cooling plate.

IPC Classes  ?

• H02K 9/19 - Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Abstract

A method of manufacturing a printed circuit board (PCB) includes forming a tridimensional (3D) dielectric substrate on a fiber-reinforced polymer with opposite sides; forming each side with channels and pockets by molding dielectric laminate, and the channels and pockets define a layout for conductive traces and pads of the PCB; forming the channels and pockets in a same side of the 3D dielectric substrate at a uniform depth; forming side walls of the channels and pockets of the 3D dielectric substrate with a draft angle in a range of greater than 0 degrees to about 5 degrees; depositing by electrolytic metallization the conductive traces and pads into the channels and pockets of the 3D dielectric substrate; and the outer surface of those conductive traces and pads are flush with the sides of the 3D dielectric substrate.

IPC Classes  ?

• H05K 3/18 - Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern using precipitation techniques to apply the conductive material
• C25D 5/02 - Electroplating of selected surface areas
• C25D 5/54 - Electroplating of non-metallic surfaces
• C25D 5/56 - Electroplating of non-metallic surfaces of plastics
• C25D 7/00 - Electroplating characterised by the article coated
• H05K 1/02 - Printed circuits Details
• H05K 1/03 - Use of materials for the substrate
• H05K 3/10 - Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern

Abstract

An axial field rotary energy device can include a rotor comprising an axis of rotation and a magnet. In addition, a stator can be coaxial with the rotor. The stator can include a plurality of stator segments that are coupled together about the axis. Each stator segment can include a printed circuit board (PCB) having a PCB layer comprising a coil. Each stator segment also can include only one electrical phase. The stator itself can include one or more electrical phases.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 1/276 - Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
• H02K 1/2795 - Rotors axially facing stators the rotor consisting of two or more circumferentially positioned magnets
• H02K 1/32 - Rotating parts of the magnetic circuit with channels or ducts for flow of cooling medium
• H02K 3/12 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 3/47 - Air-gap windings, i.e. iron-free windings
• H02K 3/52 - Fastening salient pole windings or connections thereto
• H02K 9/12 - Arrangements for cooling or ventilating by gaseous cooling medium flowing in closed circuit, a part of which is external to the machine casing wherein the cooling medium circulates freely within the casing
• H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
• H02K 16/00 - Machines with more than one rotor or stator
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 35/02 - Generators with reciprocating, oscillating or vibrating coil system, magnet, armature or other part of the magnetic circuit with moving magnets and stationary coil systems
• H02P 31/00 - Arrangements for regulating or controlling electric motors not provided for in groups , or

Abstract

A system can include an axial field rotary energy device with an axis of rotation and a rotor coaxial with the axis and having a shaft, bearings, rotor disks that are coaxial and permanent magnets on each rotor disk. A printed circuit board (PCB) stator is located between the rotor disks to define an air gap on each side of the PCB stator. An enclosure has two enclosure sections with an inspection port. Bearing caps and bearings are mounted to the rotor. A variable frequency drive (VFD) assembly is coupled to the axial field rotary energy device. The VFD has a flexible conduit that extends between the VFD housing and the axial field rotary energy device. The flexible conduit can adapt to different sizes of axial field rotary energy devices.

IPC Classes  ?

• H02K 11/33 - Drive circuits, e.g. power electronics
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 5/10 - Casings or enclosures characterised by the shape, form or construction thereof with arrangements for protection from ingress, e.g. of water or fingers
• H02K 5/173 - Means for supporting bearings, e.g. insulating supports or means for fitting bearings in the bearing-shields using bearings with rolling contact, e.g. ball bearings
• H02K 7/08 - Structural association with bearings
• H02K 9/06 - Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium with fans or impellers driven by the machine shaft
• H02K 9/22 - Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
• H02K 11/40 - Structural association with grounding devices
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Abstract

A system has an axial field rotary energy device with a housing, an axis and a rotor with a shaft, bearings, rotor disks and permanent magnets. A printed circuit board (PCB) stator is between the rotor disks to define an air gap on each side thereof. A variable frequency drive (VFD) assembly has a VFD housing and first pads coupled to inductors to facilitate heat removal from the inductors. A concave cradle is coupled to a ferromagnetic core and has a same contour as an outer surface of the ferromagnetic core. A second pad is coupled to a rectifier module. A third pad is coupled to switching devices and has pins to align the switching devices with the third pad. Standoffs are coupled to the VFD housing to support a first printed circuit board assembly (PCBA). A second PCBA is mounted to a shield plate above the first PCBA.

IPC Classes  ?

• H02K 5/06 - Cast metal casings
• H02K 5/02 - Casings or enclosures characterised by the material thereof
• H02K 11/00 - Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
• H02K 11/33 - Drive circuits, e.g. power electronics

Abstract

An axial field rotary energy device can include a housing and a rotor rotatably coupled to the housing. The rotor can have an axis of rotation and magnets. A stator assembly can be coupled to the housing coaxial with and adjacent to the rotor. The stator assembly can include a printed circuit board (PCB) having electrically conductive coils and an internal air duct for cooling the stator assembly.

IPC Classes  ?

• H02K 3/24 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors with channels or ducts for cooling medium between the conductors
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 9/06 - Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium with fans or impellers driven by the machine shaft

Abstract

An axial field rotary energy device can include a housing and a rotor coupled to the housing. The rotor can include an axis of rotation and a rotor disk having a magnet. The device can include a stator that is coaxial with the rotor. The stator can include a printed circuit board having conductive layers laminated together with layers of an insulating material. Each conductive layer has coils that can carry electrical current when connected to an external voltage source. The stator is mechanically coupled to the housing, so the stator reacts to torque produced by the device. A ferromagnetic yoke is coaxial with the rotor and stator. The ferromagnetic yoke can be mechanically and thermally coupled to the stator and the housing to provide a path for magnetic flux produced by the magnet and a path to conduct heat generated by the stator from the stator to the housing.

IPC Classes  ?

• H02K 1/2793 - Rotors axially facing stators
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Abstract

A device has a housing and a rotor with an axis and a rotor disk with a magnet. A cooling plate is coupled to the housing. The cooling plate includes a channel connected to an inlet and an outlet to convey a liquid coolant. A stator is coaxial with the rotor and includes a printed circuit board with conductive layers laminated together with layers of an insulating material. Each conductive layer has coils that can carry electrical current when connected to an external voltage source. The stator is mechanically coupled to the housing, so the stator reacts to torque produced by the device. A ferromagnetic yoke is mechanically and thermally coupled to the stator and to the cooling plate to provide a path for magnetic flux produced by the magnet and a path to conduct heat generated by the stator from the stator to the cooling plate.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 1/2793 - Rotors axially facing stators
• H02K 3/47 - Air-gap windings, i.e. iron-free windings
• H02K 11/30 - Structural association with control circuits or drive circuits

Abstract

A device has a housing, stators and a rotor with an axis and rotor disks with magnets. Each stator has a printed circuit board with conductive layers laminated together with layers of an insulating material. Each conductive layer has coils that can carry electrical current when connected to an external voltage source. The stators are mechanically coupled to the housing, so the stators react to torque produced by the device. The housing has two end sections and mid-sections where the end sections are mechanically coupled a stator and a ferromagnetic yoke. The mid-sections are mechanically coupled to one or two stators and ferromagnetic yokes. The ferromagnetic yokes are coupled to the stators and to the housing to provide a path for magnetic flux produced by the magnets and a path to conduct heat generated by the stators from the stators to the housing.

IPC Classes  ?

• H02K 3/28 - Layout of windings or of connections between windings
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Abstract

A device has a housing, stators and a rotor with an axis and rotor disks with magnets. Each stator has a printed circuit board with conductive layers laminated together with layers of an insulating material. Each conductive layer has coils that can carry electrical current when connected to an external voltage source. The stators are mechanically coupled to the housing, so the stators react to torque produced by the device. The housing has two end sections and mid-sections where the end sections are mechanically coupled a stator and a ferromagnetic yoke. The mid-sections are mechanically coupled to one or two stators and ferromagnetic yokes. The ferromagnetic yokes are coupled to the stators and to the housing to provide a path for magnetic flux produced by the magnets and a path to conduct heat generated by the stators from the stators to the housing.

IPC Classes  ?

• H02K 1/27 - Rotor cores with permanent magnets
• H02K 1/02 - Details of the magnetic circuit characterised by the magnetic material
• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 5/04 - Casings or enclosures characterised by the shape, form or construction thereof
• H02K 9/193 - Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil with provision for replenishing the cooling mediumArrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil with means for preventing leakage of the cooling medium

Abstract

An axial field rotary energy device can include a housing and a rotor coupled to the housing. The rotor can include an axis of rotation and a rotor disk having a magnet. The device can include a stator that is coaxial with the rotor. The stator can include a printed circuit board having conductive layers laminated together with layers of an insulating material. Each conductive layer has coils that can carry electrical current when connected to an external voltage source. The stator is mechanically coupled to the housing, so the stator reacts to torque produced by the device. A ferromagnetic yoke is coaxial with the rotor and stator. The ferromagnetic yoke can be mechanically and thermally coupled to the stator and the housing to provide a path for magnetic flux produced by the magnet and a path to conduct heat generated by the stator from the stator to the housing.

IPC Classes  ?

• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 9/19 - Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil

Abstract

A device has a housing and a rotor with an axis and a rotor disk with a magnet. A cooling plate is coupled to the housing. The cooling plate includes a channel connected to an inlet and an outlet to convey a liquid coolant. A stator is coaxial with the rotor and includes a printed circuit board with conductive layers laminated together with layers of an insulating material. Each conductive layer has coils that can carry electrical current when connected to an external voltage source. The stator is mechanically coupled to the housing, so the stator reacts to torque produced by the device. A ferromagnetic yoke is mechanically and thermally coupled to the stator and to the cooling plate to provide a path for magnetic flux produced by the magnet and a path to conduct heat generated by the stator from the stator to the cooling plate.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 9/19 - Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Abstract

An axial field rotary energy device can include a housing and a rotor rotatably coupled to the housing. The rotor can have an axis of rotation and magnets. A stator assembly can be coupled to the housing coaxial with and adjacent to the rotor. The stator assembly can include a printed circuit board (PCB) having electrically conductive coils and an internal air duct for cooling the stator assembly.

IPC Classes  ?

• H02K 1/20 - Stationary parts of the magnetic circuit with channels or ducts for flow of cooling medium
• H02K 11/00 - Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
• H02K 1/16 - Stator cores with slots for windings
• H02K 1/276 - Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
• H02K 1/32 - Rotating parts of the magnetic circuit with channels or ducts for flow of cooling medium
• H02K 9/06 - Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium with fans or impellers driven by the machine shaft

Abstract

A printed circuit board (PCB) has a tridimensional (3D) dielectric substrate having opposite sides and made of fiber-reinforced polymer. Each side comprises channels and pockets formed by molding a dielectric laminate, and the channels and pockets define a layout for conductive traces and pads of the PCB. The channels and pockets in a same side of the 3D dielectric substrate have a uniform depth. Side walls of the channels and pockets have a draft angle in a range of greater than 0 degrees to about 5 degrees. The conductive traces and pads are formed into the channels and pockets by electrolytic metallization. In addition, the outer surface of conductive traces and pads are flush with the sides of the 3D dielectric substrate.

IPC Classes  ?

• H02K 1/02 - Details of the magnetic circuit characterised by the magnetic material
• H05K 1/02 - Printed circuits Details
• H05K 1/03 - Use of materials for the substrate
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H05K 3/18 - Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern using precipitation techniques to apply the conductive material

Abstract

An axial field rotary energy device are disclosed. For example, the device can include a printed circuit board (PCB) stator having PCB panels. Each PCB panel can include conductive layers. Selected ones of the conductive layers are coupled to plated vias that extend from one major surface of the PCB stator to an opposite major surface of the PCB stator. In addition, each major surface of the PCB stator can have a layer of a dielectric material that completely covers ends of the plated vias.

IPC Classes  ?

• H02K 11/30 - Structural association with control circuits or drive circuits
• H02K 35/02 - Generators with reciprocating, oscillating or vibrating coil system, magnet, armature or other part of the magnetic circuit with moving magnets and stationary coil systems
• H02K 1/2798 - Rotors axially facing stators the rotor consisting of two or more circumferentially positioned magnets where both axial sides of the stator face a rotor
• H02K 1/14 - Stator cores with salient poles

Abstract

A motor includes a stator and a rotor having an axis of rotation and a magnet. The stator includes a PCB having PCB panels. Each PCB panel is assigned to one electrical phase. Each PCB panel has a pair of PCB layers. Each PCB layer includes coils, and each coil in each PCB layer of a PCB panel is circumferentially aligned with a corresponding coil in another PCB layer. One coil in one PCB layer is coupled to a corresponding coil in another PCB layer with a via. A number of turns in each coil is a multiple of a number of electrical phases configured for the PCB stator. In addition, the vias that connect two coils in a pair of PCB layers that belong to a same electrical phase do not intersect coils in PCB layers that belong to other electrical phases of the PCB stator.

IPC Classes  ?

• H02K 11/30 - Structural association with control circuits or drive circuits
• H02K 35/02 - Generators with reciprocating, oscillating or vibrating coil system, magnet, armature or other part of the magnetic circuit with moving magnets and stationary coil systems
• H02K 1/2798 - Rotors axially facing stators the rotor consisting of two or more circumferentially positioned magnets where both axial sides of the stator face a rotor
• H02K 1/14 - Stator cores with salient poles

Abstract

An axial field rotary energy device or system includes an axis, a PCB stator and rotors having respective permanent magnets. The rotors rotate about the axis relative to the PCB stator. A variable frequency drive (VFD) having VFD components are coupled to the axial field rotary energy device. An enclosure contains the axial field rotary energy device and the VFD, such that the axial field rotary device and the VFD are integrated together within the enclosure. In addition, a cooling system is integrated with the enclosure to cool the axial field rotary energy device and the VFD.

IPC Classes  ?

• H02K 1/2795 - Rotors axially facing stators the rotor consisting of two or more circumferentially positioned magnets
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 11/33 - Drive circuits, e.g. power electronics
• H02K 16/02 - Machines with one stator and two rotors
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02P 27/06 - Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage using DC to AC converters or inverters

Abstract

A device has a housing and rotors rotatably coupled to the housing. Each rotor has a magnet on at least one side of the rotor. Printed circuit board (PCB) stators are located axially between the rotors and coupled to the housing. The PCB stators have layers, and each layer has coils. The number of rotors disks is equal to the number of stators plus one. The stators are interleaved with the rotors. A shaft is coupled to the rotors and the housing. The shaft has a hollow section coupled to a source of a liquid coolant through a rotary connector and to radial channels in the shaft that dispense a liquid coolant between the rotors and PCB stators. The shaft has flanges with different diameters configured to receive the rotors disks with respective matching bore diameters. In addition, the housing has a sump to collect the liquid coolant.

IPC Classes  ?

• H02K 5/20 - Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium
• H02K 1/2798 - Rotors axially facing stators the rotor consisting of two or more circumferentially positioned magnets where both axial sides of the stator face a rotor
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 7/00 - Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
• H02K 9/19 - Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Abstract

A motor includes a stator and a rotor having an axis of rotation and a magnet. The stator includes a PCB having PCB panels. Each PCB panel is assigned to one electrical phase. Each PCB panel has a pair of PCB layers. Each PCB layer includes coils, and each coil in each PCB layer of a PCB panel is circumferentially aligned with a corresponding coil in another PCB layer. One coil in one PCB layer is coupled to a corresponding coil in another PCB layer with a via. A number of turns in each coil is a multiple of a number of electrical phases configured for the PCB stator. In addition, the vias that connect two coils in a pair of PCB layers that belong to a same electrical phase do not intersect coils in PCB layers that belong to other electrical phases of the PCB stator.

IPC Classes  ?

• H02K 11/30 - Structural association with control circuits or drive circuits
• H02K 1/2798 - Rotors axially facing stators the rotor consisting of two or more circumferentially positioned magnets where both axial sides of the stator face a rotor
• H02K 35/02 - Generators with reciprocating, oscillating or vibrating coil system, magnet, armature or other part of the magnetic circuit with moving magnets and stationary coil systems
• H02K 1/14 - Stator cores with salient poles

Abstract

A device has a housing and rotors rotatably coupled to the housing. Each rotor has a magnet on at least one side of the rotor. Printed circuit board (PCB) stators are located axially between the rotors and coupled to the housing. The PCB stators have layers, and each layer has coils. The number of rotors disks is equal to the number of stators plus one. The stators are interleaved with the rotors. A shaft is coupled to the rotors and the housing. The shaft has a hollow section coupled to a source of a liquid coolant through a rotary connector and to radial channels in the shaft that dispense a liquid coolant between the rotors and PCB stators. The shaft has flanges with different diameters configured to receive the rotors disks with respective matching bore diameters. In addition, the housing has a sump to collect the liquid coolant.

IPC Classes  ?

• H02K 9/19 - Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 1/2793 - Rotors axially facing stators
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Abstract

A device has a housing and rotors rotatably coupled to the housing. Each rotor has a magnet on at least one side of the rotor. Printed circuit board (PCB) stators are located axially between the rotors and coupled to the housing. The PCB stators have layers, and each layer has coils. The number of rotors disks is equal to the number of stators plus one. The stators are interleaved with the rotors. A shaft is coupled to the rotors and the housing. The shaft has a hollow section coupled to a source of a liquid coolant through a rotary connector and to radial channels in the shaft that dispense a liquid coolant between the rotors and PCB stators. The shaft has flanges with different diameters configured to receive the rotors disks with respective matching bore diameters. In addition, the housing has a sump to collect the liquid coolant.

IPC Classes  ?

• H02K 9/19 - Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil
• H02K 5/20 - Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium
• H02K 1/2798 - Rotors axially facing stators the rotor consisting of two or more circumferentially positioned magnets where both axial sides of the stator face a rotor
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 7/00 - Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines

Abstract

An axial field rotary energy system has a housing and rotors with an axis of rotation that are rotatably coupled to the housing. Each rotor includes a magnet. A stator assembly is located axially between the rotors and coupled to the housing. The stator assembly has a printed circuit board (PCB). The PCB includes a plurality of layers, and each layer has coils. A shaft is coupled to the rotors and the housing. The shaft can dispense a liquid coolant between the rotors and stator assembly. The housing can include a sump to collect the liquid coolant.

IPC Classes  ?

• H02K 9/19 - Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil
• H02K 9/193 - Arrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil with provision for replenishing the cooling mediumArrangements for cooling or ventilating for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil with means for preventing leakage of the cooling medium
• H02K 5/20 - Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium
• H02K 7/00 - Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Abstract

An axial field rotary energy device has a PCB stator panel assembly between rotors with an axis of rotation. Each rotor has a magnet. The PCB stator panel assembly includes PCB panels. Each PCB panel can have layers, and each layer can have conductive coils. The PCB stator panel assembly can have a thermally conductive layer that extends from an inner diameter portion to an outer diameter portion thereof.

IPC Classes  ?

• H02K 9/22 - Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
• H01F 17/00 - Fixed inductances of the signal type
• H01F 27/22 - Cooling by heat conduction through solid or powdered fillings
• H01F 27/28 - CoilsWindingsConductive connections
• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 11/26 - Devices for sensing voltage, or actuated thereby, e.g. overvoltage protection devices
• H02K 11/30 - Structural association with control circuits or drive circuits
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H05K 1/02 - Printed circuits Details
• H05K 1/11 - Printed elements for providing electric connections to or between printed circuits
• H05K 1/16 - Printed circuits incorporating printed electric components, e.g. printed resistor, capacitor, inductor

Abstract

An axial field rotary energy device can include a housing and a rotor rotatably coupled to the housing. The rotor can have an axis of rotation and magnets. A stator assembly can be coupled to the housing coaxial with and adjacent to the rotor. The stator assembly can include a printed circuit board (PCB) having electrically conductive coils and an internal air duct for cooling the stator assembly.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 3/24 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors with channels or ducts for cooling medium between the conductors
• H02K 11/30 - Structural association with control circuits or drive circuits
• H02K 11/33 - Drive circuits, e.g. power electronics

Abstract

An axial field rotary energy device can include a rotor comprising an axis of rotation and a magnet. In addition, a stator can be coaxial with the rotor. The stator can include a plurality of stator segments that are coupled together about the axis. Each stator segment can include a printed circuit board (PCB) having a PCB layer comprising a coil. Each stator segment also can include only one electrical phase. The stator itself can include one or more electrical phases.

IPC Classes  ?

• H02K 1/2795 - Rotors axially facing stators the rotor consisting of two or more circumferentially positioned magnets
• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 1/276 - Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
• H02K 1/32 - Rotating parts of the magnetic circuit with channels or ducts for flow of cooling medium
• H02K 3/12 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 3/47 - Air-gap windings, i.e. iron-free windings
• H02K 3/52 - Fastening salient pole windings or connections thereto
• H02K 9/12 - Arrangements for cooling or ventilating by gaseous cooling medium flowing in closed circuit, a part of which is external to the machine casing wherein the cooling medium circulates freely within the casing
• H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
• H02K 16/00 - Machines with more than one rotor or stator
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 35/02 - Generators with reciprocating, oscillating or vibrating coil system, magnet, armature or other part of the magnetic circuit with moving magnets and stationary coil systems
• H02P 31/00 - Arrangements for regulating or controlling electric motors not provided for in groups , or

Abstract

An axial field rotary energy device or system includes an axis, a PCB stator and rotors having respective permanent magnets. The rotors rotate about the axis relative to the PCB stator. A variable frequency drive (VFD) having VFD components are coupled to the axial field rotary energy device. An enclosure contains the axial field rotary energy device and the VFD, such that the axial field rotary device and the VFD are integrated together within the enclosure. In addition, a cooling system is integrated with the enclosure to cool the axial field rotary energy device and the VFD.

IPC Classes  ?

• H02K 1/32 - Rotating parts of the magnetic circuit with channels or ducts for flow of cooling medium
• H02K 5/04 - Casings or enclosures characterised by the shape, form or construction thereof
• H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
• H02K 16/02 - Machines with one stator and two rotors

Abstract

An axial field rotary energy device or system includes an axis, a PCB stator and rotors having respective permanent magnets. The rotors rotate about the axis relative to the PCB stator. A variable frequency drive (VFD) having VFD components are coupled to the axial field rotary energy device. An enclosure contains the axial field rotary energy device and the VFD, such that the axial field rotary device and the VFD are integrated together within the enclosure. In addition, a cooling system is integrated with the enclosure to cool the axial field rotary energy device and the VFD.

IPC Classes  ?

• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 1/27 - Rotor cores with permanent magnets
• H02K 9/02 - Arrangements for cooling or ventilating by ambient air flowing through the machine
• H02K 9/12 - Arrangements for cooling or ventilating by gaseous cooling medium flowing in closed circuit, a part of which is external to the machine casing wherein the cooling medium circulates freely within the casing
• H02K 11/33 - Drive circuits, e.g. power electronics
• H02K 11/30 - Structural association with control circuits or drive circuits

Abstract

An axial field rotary energy device has a PCB stator panel assembly between rotors with an axis of rotation. Each rotor has a magnet. The PCB stator panel assembly includes PCB panels. Each PCB panel can have layers, and each layer can have conductive coils. The PCB stator panel assembly can have a thermally conductive layer that extends from an inner diameter portion to an outer diameter portion thereof. Each PCB panel comprises discrete, PCB radial segments that are mechanically and electrically coupled together to form the respective PCB panels.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
• H02K 3/47 - Air-gap windings, i.e. iron-free windings

Abstract

An axial field rotary energy device with a PCB stator having interleaved PCBs is disclosed. The device can include rotors that have magnets and an axis of rotation. A stator assembly can be located axially between the rotors to operate electrical phases. The stator assembly can include PCB panels. Each PCB panel can have layers, and each PCB panel can be designated to one of the electrical phases. Each electrical phase of the stator assembly can be provided by a plurality of the PCB panels. In addition, the PCB panels for each electrical phase can be axially spaced apart from and intermingled with each other.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 9/22 - Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
• H05K 1/16 - Printed circuits incorporating printed electric components, e.g. printed resistor, capacitor, inductor
• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 11/26 - Devices for sensing voltage, or actuated thereby, e.g. overvoltage protection devices
• H02K 11/30 - Structural association with control circuits or drive circuits
• H01F 17/00 - Fixed inductances of the signal type
• H01F 27/22 - Cooling by heat conduction through solid or powdered fillings
• H01F 27/28 - CoilsWindingsConductive connections
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H05K 1/02 - Printed circuits Details
• H05K 1/11 - Printed elements for providing electric connections to or between printed circuits

Abstract

An axial field rotary energy device can include rotors having magnets and an axis of rotation. A stator assembly can be located axially between the rotors. The stator assembly can include PCB panels. Each PCB panel can have layers. Each layer can include coils. Each coil can have radial traces relative to the axis. The radial traces can include non-linear radial traces coupled by arch traces that are transverse to the non-linear radial traces.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 9/22 - Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
• H05K 1/16 - Printed circuits incorporating printed electric components, e.g. printed resistor, capacitor, inductor
• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 11/26 - Devices for sensing voltage, or actuated thereby, e.g. overvoltage protection devices
• H02K 11/30 - Structural association with control circuits or drive circuits
• H01F 17/00 - Fixed inductances of the signal type
• H01F 27/22 - Cooling by heat conduction through solid or powdered fillings
• H01F 27/28 - CoilsWindingsConductive connections
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H05K 1/02 - Printed circuits Details
• H05K 1/11 - Printed elements for providing electric connections to or between printed circuits

Abstract

An axial field rotary energy device has a PCB stator panel assembly between rotors with an axis of rotation. Each rotor has a magnet. The PCB stator panel assembly includes PCB panels. Each PCB panel can have layers, and each layer can have conductive coils. The PCB stator panel assembly can have a thermally conductive layer that extends from an inner diameter portion to an outer diameter portion thereof. Each PCB panel comprises discrete, PCB radial segments that are mechanically and electrically coupled together to form the respective PCB panels.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 9/22 - Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
• H05K 1/16 - Printed circuits incorporating printed electric components, e.g. printed resistor, capacitor, inductor
• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 11/26 - Devices for sensing voltage, or actuated thereby, e.g. overvoltage protection devices
• H02K 11/30 - Structural association with control circuits or drive circuits
• H01F 17/00 - Fixed inductances of the signal type
• H01F 27/22 - Cooling by heat conduction through solid or powdered fillings
• H01F 27/28 - CoilsWindingsConductive connections
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H05K 1/02 - Printed circuits Details
• H05K 1/11 - Printed elements for providing electric connections to or between printed circuits

Abstract

An axial field rotary energy device has a PCB stator panel assembly between rotors with an axis of rotation. Each rotor has a magnet. The PCB stator panel assembly includes PCB panels. Each PCB panel can have layers, and each layer can have conductive coils. The PCB stator panel assembly can have a thermally conductive layer that extends from an inner diameter portion to an outer diameter portion thereof.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 9/22 - Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
• H05K 1/16 - Printed circuits incorporating printed electric components, e.g. printed resistor, capacitor, inductor
• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 11/26 - Devices for sensing voltage, or actuated thereby, e.g. overvoltage protection devices
• H02K 11/30 - Structural association with control circuits or drive circuits
• H01F 17/00 - Fixed inductances of the signal type
• H01F 27/22 - Cooling by heat conduction through solid or powdered fillings
• H01F 27/28 - CoilsWindingsConductive connections
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H05K 1/02 - Printed circuits Details
• H05K 1/11 - Printed elements for providing electric connections to or between printed circuits

Abstract

An axial field rotary energy device or system includes an axis, a PCB stator and rotors having respective permanent magnets. The rotors rotate about the axis relative to the PCB stator. A variable frequency drive (VFD) having VFD components are coupled to the axial field rotary energy device. An enclosure contains the axial field rotary energy device and the VFD, such that the axial field rotary device and the VFD are integrated together within the enclosure. In addition, a cooling system is integrated with the enclosure to cool the axial field rotary energy device and the VFD.

IPC Classes  ?

• H02K 9/06 - Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium with fans or impellers driven by the machine shaft
• H02K 5/20 - Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 16/02 - Machines with one stator and two rotors
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 1/27 - Rotor cores with permanent magnets
• H02P 27/06 - Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage using DC to AC converters or inverters
• H02K 11/33 - Drive circuits, e.g. power electronics

Abstract

An axial field rotary energy device or system includes an axis, a PCB stator and rotors having respective permanent magnets. The rotors rotate about the axis relative to the PCB stator. A variable frequency drive (VFD) having VFD components are coupled to the axial field rotary energy device. An enclosure contains the axial field rotary energy device and the VFD, such that the axial field rotary device and the VFD are integrated together within the enclosure. In addition, a cooling system is integrated with the enclosure to cool the axial field rotary energy device and the VFD.

IPC Classes  ?

• H02K 1/2793 - Rotors axially facing stators
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 5/18 - Casings or enclosures characterised by the shape, form or construction thereof with ribs or fins for improving heat transfer
• H02K 9/06 - Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium with fans or impellers driven by the machine shaft
• H02K 11/33 - Drive circuits, e.g. power electronics
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02P 27/06 - Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage using DC to AC converters or inverters
• H02K 16/02 - Machines with one stator and two rotors
• H02K 5/20 - Casings or enclosures characterised by the shape, form or construction thereof with channels or ducts for flow of cooling medium

Abstract

An axial field rotary energy device can include a rotor comprising an axis of rotation and a magnet. In addition, a stator can be coaxial with the rotor. The stator can include a plurality of stator segments that are coupled together about the axis. Each stator segment can include a printed circuit board (PCB) having a PCB layer comprising a coil. Each stator segment also can include only one electrical phase. The stator itself can include one or more electrical phases.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 3/47 - Air-gap windings, i.e. iron-free windings
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 3/52 - Fastening salient pole windings or connections thereto
• H02K 1/2795 - Rotors axially facing stators the rotor consisting of two or more circumferentially positioned magnets
• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 1/32 - Rotating parts of the magnetic circuit with channels or ducts for flow of cooling medium
• H02K 9/12 - Arrangements for cooling or ventilating by gaseous cooling medium flowing in closed circuit, a part of which is external to the machine casing wherein the cooling medium circulates freely within the casing
• H02K 16/00 - Machines with more than one rotor or stator
• H02P 31/00 - Arrangements for regulating or controlling electric motors not provided for in groups , or
• H02K 1/276 - Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
• H02K 3/12 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
• H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
• H02K 35/02 - Generators with reciprocating, oscillating or vibrating coil system, magnet, armature or other part of the magnetic circuit with moving magnets and stationary coil systems

Abstract

An axial field rotary energy device can include a housing having an axis with an axial direction. A stator assembly can include stator panels that are discrete panels from each other. The stators panels can be mechanically and stationarily coupled to the housing. Each stator panel can include a printed circuit board (PCB) having coils that are electrically conductive, and each stator panel can operate with a single electrical phase. In addition, rotors can be rotatably mounted within the housing on opposite axial ends of the stator assembly. The rotors can be mechanically coupled together with a rotor spacer. Each rotor can include magnets. In addition, in one version, no rotor is disposed between axially adjacent ones of the stator panels.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 11/30 - Structural association with control circuits or drive circuits
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 1/27 - Rotor cores with permanent magnets
• H02K 3/47 - Air-gap windings, i.e. iron-free windings
• H02K 11/215 - Magnetic effect devices, e.g. Hall-effect or magneto-resistive elements

Goods & Services

Electric motors for machines; electric generators

Goods & Services

Electric motors for machines; electric generators

Abstract

An axial field rotary energy device can include a housing having an axis. A stator assembly is mounted to the housing and has stator panels that are axially-stacked and discrete panels from each other. Each stator panel includes a respective printed circuit board (PCB) having respective coils that are electrically conductive and interconnected within the respective PCB. In addition, a rotor assembly including rotors is rotatably mounted within the housing on opposite axial ends of the stator assembly. The rotors can be mechanically coupled together. Each rotor can include magnets having leading and trailing edges. The trailing edge of one magnet and the leading edge of an adjacent magnet can be parallel to each other to define a consistent circumferential spacing, relative to the axis, between adjacent ones of the magnets.

IPC Classes  ?

• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 3/04 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 15/02 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
• H02K 15/04 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings prior to their mounting into the machines
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 1/27 - Rotor cores with permanent magnets

Abstract

An axial field rotary energy device can include a housing having an axis with an axial direction. A stator assembly can include a plurality of stator panels that are discrete panels from each other. The stators panels can be mechanically and stationarily coupled to the housing. Each stator panel can include a printed circuit board (PCB) having coils that are electrically conductive, each stator panel consists of a single electrical phase. In addition, rotors can be rotatably mounted within the housing on opposite axial ends of the stator assembly. The rotors can be mechanically coupled together with a rotor spacer. Each rotor can include magnets. In addition, in one version, no rotor is disposed between axially adjacent ones of the stator panels.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 1/27 - Rotor cores with permanent magnets

Abstract

An axial field rotary energy device can include a rotor comprising an axis of rotation and a magnet. In addition, a stator can be coaxial with the rotor. The stator can include a plurality of stator segments that are coupled together about the axis. Each stator segment can include a printed circuit board (PCB) having a PCB layer comprising a coil. Each stator segment also can include only one electrical phase. The stator itself can include one or more electrical phases.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 3/47 - Air-gap windings, i.e. iron-free windings
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 1/27 - Rotor cores with permanent magnets
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 3/52 - Fastening salient pole windings or connections thereto
• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 1/32 - Rotating parts of the magnetic circuit with channels or ducts for flow of cooling medium
• H02K 9/12 - Arrangements for cooling or ventilating by gaseous cooling medium flowing in closed circuit, a part of which is external to the machine casing wherein the cooling medium circulates freely within the casing
• H02K 16/00 - Machines with more than one rotor or stator
• H02P 31/00 - Arrangements for regulating or controlling electric motors not provided for in groups , or
• H02K 3/12 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
• H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
• H02K 35/02 - Generators with reciprocating, oscillating or vibrating coil system, magnet, armature or other part of the magnetic circuit with moving magnets and stationary coil systems

Abstract

An axial field rotary energy device can include a housing having an axis with an axial direction. A stator assembly can include a plurality of stator panels that are discrete panels from each other. The stators panels can be mechanically and stationarily coupled to the housing. Each stator panel can include a printed circuit board (PCB) having coils that are electrically conductive, each stator panel consists of a single electrical phase. In addition, rotors can be rotatably mounted within the housing on opposite axial ends of the stator assembly. The rotors can be mechanically coupled together with a rotor spacer. Each rotor can include magnets. In addition, in one version, no rotor is disposed between axially adjacent ones of the stator panels.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 3/47 - Air-gap windings, i.e. iron-free windings
• H02K 1/27 - Rotor cores with permanent magnets
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 11/30 - Structural association with control circuits or drive circuits
• H02K 11/215 - Magnetic effect devices, e.g. Hall-effect or magneto-resistive elements

Abstract

An axial field rotary energy device can include a rotor having an axis of rotation and a magnet; a stator coaxial with the rotor, the stator can have a printed circuit board (PCB) having a plurality of PCB layers that are spaced apart in an axial direction, each PCB layer can include a coil having only two terminals for electrical connections, each coil is continuous and uninterrupted between its only two terminals, each coil consists of a single electrical phase, and one of the two terminals of each coil is electrically coupled to another coil with a via to define a coil pair; and each coil pair is electrically coupled to another coil pair with another via.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 1/32 - Rotating parts of the magnetic circuit with channels or ducts for flow of cooling medium
• H02K 1/27 - Rotor cores with permanent magnets
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 3/47 - Air-gap windings, i.e. iron-free windings
• H02K 3/52 - Fastening salient pole windings or connections thereto
• H02K 9/12 - Arrangements for cooling or ventilating by gaseous cooling medium flowing in closed circuit, a part of which is external to the machine casing wherein the cooling medium circulates freely within the casing
• H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
• H02K 16/00 - Machines with more than one rotor or stator
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02P 31/00 - Arrangements for regulating or controlling electric motors not provided for in groups , or
• H02K 3/12 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
• H02K 35/02 - Generators with reciprocating, oscillating or vibrating coil system, magnet, armature or other part of the magnetic circuit with moving magnets and stationary coil systems

Abstract

An axial field rotary energy device can include a housing having an axis. A stator assembly is mounted to the housing and has stator panels that are axially-stacked and discrete panels from each other. Each stator panel includes a respective printed circuit board (PCB) having respective coils that are electrically conductive and interconnected within the respective PCB. In addition, a rotor assembly including rotors is rotatably mounted within the housing on opposite axial ends of the stator assembly. The rotors can be mechanically coupled together. Each rotor can include magnets having leading and trailing edges. The trailing edge of one magnet and the leading edge of an adjacent magnet can be parallel to each other to define a consistent circumferential spacing, relative to the axis, between adjacent ones of the magnets.

IPC Classes  ?

• H02K 16/02 - Machines with one stator and two rotors
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 1/27 - Rotor cores with permanent magnets
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 11/30 - Structural association with control circuits or drive circuits
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 5/04 - Casings or enclosures characterised by the shape, form or construction thereof
• H02K 16/00 - Machines with more than one rotor or stator
• H02K 5/173 - Means for supporting bearings, e.g. insulating supports or means for fitting bearings in the bearing-shields using bearings with rolling contact, e.g. ball bearings

Abstract

An axial field rotary energy device can include a housing having an axis with an axial direction. A stator assembly can include a plurality of stator panels that are discrete panels from each other. The stators panels can be mechanically and stationarily coupled to the housing. Each stator panel can include a printed circuit board (PCB) having coils that are electrically conductive, each stator panel consists of a single electrical phase. In addition, rotors can be rotatably mounted within the housing on opposite axial ends of the stator assembly. The rotors can be mechanically coupled together with a rotor spacer. Each rotor can include magnets. In addition, in one version, no rotor is disposed between axially adjacent ones of the stator panels.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 3/47 - Air-gap windings, i.e. iron-free windings
• H02K 1/27 - Rotor cores with permanent magnets
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 11/30 - Structural association with control circuits or drive circuits
• H02K 11/215 - Magnetic effect devices, e.g. Hall-effect or magneto-resistive elements

Abstract

An axial field rotary energy device (31) can include a rotor (33) comprising an axis (35) of rotation and a magnet (37). In addition, a stator (141) can be coaxial with the rotor. The stator can include a plurality of stator segments (142) that are coupled together about the axis. Each stator segment can include a printed circuit board (PCB) (145) having a PCB layer (147) comprising a coil (149). Each stator segment also can include only one electrical phase. The stator itself can include one or more electrical phases.

IPC Classes  ?

• H02K 1/22 - Rotating parts of the magnetic circuit
• H02K 1/27 - Rotor cores with permanent magnets
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 3/46 - Fastening of windings on the stator or rotor structure
• H02K 9/04 - Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium
• H02K 9/22 - Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
• H02K 11/33 - Drive circuits, e.g. power electronics
• H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
• H02K 15/08 - Forming windings by laying conductors into or around core parts
• H02K 17/04 - Asynchronous induction motors for single phase current
• H02K 17/12 - Asynchronous induction motors for multi-phase current
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Abstract

A system for an axial field rotary energy device (31) can include modules (201) that each are an axial field rotary energy device (31). The modules can be connected together for a desired power input or output. Each module can include a housing (203) having an axis (235). The housing can be mechanically coupled to at least one other module. In addition, the housing can be electrically coupled to one other module. Rotors (233) can be rotatably mounted to the housing. Each rotor can include magnets (237). The housing also can have stators (241). Each stator can include a printed circuit board (PCB) (245) having PCB layers (147) comprising coils (149).

IPC Classes  ?

• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 1/27 - Rotor cores with permanent magnets
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 3/46 - Fastening of windings on the stator or rotor structure
• H02K 9/22 - Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
• H02K 11/33 - Drive circuits, e.g. power electronics
• H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
• H02K 15/08 - Forming windings by laying conductors into or around core parts
• H02K 17/04 - Asynchronous induction motors for single phase current
• H02K 17/12 - Asynchronous induction motors for multi-phase current
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Abstract

An axial field rotary energy device (31) can include a rotor (33) having an axis (35) of rotation and a magnet (37). A stator (41) can be coaxial with the rotor. The stator can have a printed circuit board (PCB) (45) having a plurality of PCB layers (47) that are spaced apart in an axial direction. Each PCB layer can include a coil (49) having only two terminals (51, 53) for electrical connections. Each coil can be continuous and uninterrupted between its only two terminals. Each coil can consist of a single electrical phase. One of the two terminals of each coil can be electrically coupled to another coil with a via (55) to define a coil pair (57). Each coil pair can be electrically coupled to another coil pair with another via (59).

IPC Classes  ?

• H02K 1/22 - Rotating parts of the magnetic circuit
• H02K 1/27 - Rotor cores with permanent magnets
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 3/46 - Fastening of windings on the stator or rotor structure
• H02K 9/04 - Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium
• H02K 9/22 - Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
• H02K 11/33 - Drive circuits, e.g. power electronics
• H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
• H02K 15/08 - Forming windings by laying conductors into or around core parts
• H02K 17/04 - Asynchronous induction motors for single phase current
• H02K 17/12 - Asynchronous induction motors for multi-phase current
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Abstract

A module (201) can be an axial field rotary energy device (31) including a housing (203) having coupling structures (209) configured to mechanically couple the housing to a second housing (203) of a second module (201). In addition, the housing can include electrical elements (204) configured to electrically couple the housing to the second housing. A rotor (233) can be rotatably mounted to the housing. The rotor can include an axis (235) and a magnet (237). A stator (241) can be mounted to the housing coaxially with the rotor. The stator can include a printed circuit board (PCB) (245) having a PCB layer (147) comprising a coil (149).

IPC Classes  ?

• H02K 1/22 - Rotating parts of the magnetic circuit
• H02K 1/27 - Rotor cores with permanent magnets
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 3/46 - Fastening of windings on the stator or rotor structure
• H02K 9/04 - Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium
• H02K 9/22 - Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
• H02K 11/33 - Drive circuits, e.g. power electronics
• H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
• H02K 15/08 - Forming windings by laying conductors into or around core parts
• H02K 17/04 - Asynchronous induction motors for single phase current
• H02K 17/12 - Asynchronous induction motors for multi-phase current
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Abstract

An axial field rotary energy device (31) can include a housing (203). A rotor (233) can be mounted inside the housing. The rotor can include an axis (235) of rotation and a magnet (237). A stator (311) also can be mounted inside the housing coaxial with the rotor. The stator can include a printed circuit board (PCB) (245) having a PCB layer (247) with a coil (313). A sensor (342) can be integrated within the housing. The sensor can be configured to monitor, detect or generate data regarding operation of the axial field rotary energy device.

IPC Classes  ?

• H02K 1/22 - Rotating parts of the magnetic circuit
• H02K 1/27 - Rotor cores with permanent magnets
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 3/46 - Fastening of windings on the stator or rotor structure
• H02K 9/04 - Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium
• H02K 9/22 - Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
• H02K 11/33 - Drive circuits, e.g. power electronics
• H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
• H02K 15/08 - Forming windings by laying conductors into or around core parts
• H02K 17/04 - Asynchronous induction motors for single phase current
• H02K 17/12 - Asynchronous induction motors for multi-phase current
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Abstract

An axial field rotary energy device (31) can include a rotor (33) having an axis (35) of rotation and magnets (37). Each magnet can extend in a radial direction relative to the axis. Each magnet can include a magnet radial edge (67). The device also includes a stator (41) that is coaxial with the rotor. The stator has printed circuit board (PCB) layers (47) each having coils (49). Each coil has a coil radial edge (69). When the radial edge portions of the magnets and the coils rotationally align relative to the axis, the magnet radial edges (67) and the coil radial edges (69) are not parallel and are angularly skewed relative to each other.

IPC Classes  ?

• H02K 1/22 - Rotating parts of the magnetic circuit
• H02K 1/27 - Rotor cores with permanent magnets
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 3/46 - Fastening of windings on the stator or rotor structure
• H02K 9/04 - Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium
• H02K 9/22 - Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
• H02K 11/33 - Drive circuits, e.g. power electronics
• H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
• H02K 15/08 - Forming windings by laying conductors into or around core parts
• H02K 17/04 - Asynchronous induction motors for single phase current
• H02K 17/12 - Asynchronous induction motors for multi-phase current
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Abstract

An axial field rotary energy device (31) can include a housing (203). A rotor (33) can be mounted inside the housing. The rotor can include an axis (35) of rotation and a magnet (37). A stator (41) can be mounted inside the housing coaxial with the rotor. The stator can include a printed circuit board (PCB) (45) having a PCB layer (47) with a trace (49) that is electrically conductive. The trace can include radial traces (150) that extend in a radial direction relative to the axis and end turn traces (148) that extend between the radial traces. The trace can include slits (321) that extend through at least some portions of the trace.

IPC Classes  ?

• H02K 1/22 - Rotating parts of the magnetic circuit
• H02K 1/27 - Rotor cores with permanent magnets
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 3/46 - Fastening of windings on the stator or rotor structure
• H02K 9/04 - Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium
• H02K 9/22 - Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
• H02K 11/33 - Drive circuits, e.g. power electronics
• H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
• H02K 15/08 - Forming windings by laying conductors into or around core parts
• H02K 17/04 - Asynchronous induction motors for single phase current
• H02K 17/12 - Asynchronous induction motors for multi-phase current
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Abstract

An axial field rotary energy device can include a housing having coupling structures configured to mechanically couple the housing to a second housing of a second module. In addition, the housing can include electrical elements configured to electrically couple the housing to the second housing. A rotor can be rotatably mounted to the housing. The rotor can include an axis and a magnet. A stator can be mounted to the housing coaxially with the rotor. The stator can include a printed circuit board (PCB) having a PCB layer comprising a coil.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 1/27 - Rotor cores with permanent magnets
• H02K 3/47 - Air-gap windings, i.e. iron-free windings
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 1/32 - Rotating parts of the magnetic circuit with channels or ducts for flow of cooling medium
• H02K 9/12 - Arrangements for cooling or ventilating by gaseous cooling medium flowing in closed circuit, a part of which is external to the machine casing wherein the cooling medium circulates freely within the casing
• H02K 16/00 - Machines with more than one rotor or stator
• H02P 31/00 - Arrangements for regulating or controlling electric motors not provided for in groups , or
• H02K 3/12 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
• H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
• H02K 35/02 - Generators with reciprocating, oscillating or vibrating coil system, magnet, armature or other part of the magnetic circuit with moving magnets and stationary coil systems
• H02K 3/52 - Fastening salient pole windings or connections thereto

Abstract

A system for an axial field rotary energy device can include modules that each are an axial field rotary energy device. The modules can be connected together for a desired power input or output. Each module can include a housing having an axis. The housing can be mechanically coupled to at least one other module. In addition, the housing can be electrically coupled to one other module. Rotors can be rotatably mounted to the housing. Each rotor can include magnets. The housing also can have stators. Each stator can include a printed circuit board (PCB) having PCB layers comprising coils.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 16/00 - Machines with more than one rotor or stator
• H02K 31/00 - Acyclic motors or generators, i.e. DC machines having drum or disc armatures with continuous current collectors
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 1/27 - Rotor cores with permanent magnets
• H02K 3/47 - Air-gap windings, i.e. iron-free windings
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 1/32 - Rotating parts of the magnetic circuit with channels or ducts for flow of cooling medium
• H02K 9/12 - Arrangements for cooling or ventilating by gaseous cooling medium flowing in closed circuit, a part of which is external to the machine casing wherein the cooling medium circulates freely within the casing
• H02P 31/00 - Arrangements for regulating or controlling electric motors not provided for in groups , or
• H02K 3/12 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
• H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
• H02K 35/02 - Generators with reciprocating, oscillating or vibrating coil system, magnet, armature or other part of the magnetic circuit with moving magnets and stationary coil systems
• H02K 3/52 - Fastening salient pole windings or connections thereto

Abstract

An axial field rotary energy device can include a rotor having an axis of rotation and a magnet; a stator coaxial with the rotor, the stator can have a printed circuit board (PCB) having a plurality of PCB layers that are spaced apart in an axial direction, each PCB layer can include a coil having only two terminals for electrical connections, each coil is continuous and uninterrupted between its only two terminals, each coil consists of a single electrical phase, and one of the two terminals of each coil is electrically coupled to another coil with a via to define a coil pair; and each coil pair is electrically coupled to another coil pair with another via.

IPC Classes  ?

• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
• H02K 35/02 - Generators with reciprocating, oscillating or vibrating coil system, magnet, armature or other part of the magnetic circuit with moving magnets and stationary coil systems
• H02K 1/27 - Rotor cores with permanent magnets
• H02K 3/12 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 3/47 - Air-gap windings, i.e. iron-free windings
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 1/32 - Rotating parts of the magnetic circuit with channels or ducts for flow of cooling medium
• H02K 9/12 - Arrangements for cooling or ventilating by gaseous cooling medium flowing in closed circuit, a part of which is external to the machine casing wherein the cooling medium circulates freely within the casing
• H02K 16/00 - Machines with more than one rotor or stator
• H02P 31/00 - Arrangements for regulating or controlling electric motors not provided for in groups , or
• H02K 3/52 - Fastening salient pole windings or connections thereto

Abstract

An axial field rotary energy device can include a rotor comprising an axis of rotation and a magnet. In addition, a stator can be coaxial with the rotor. The stator can include a plurality of stator segments that are coupled together about the axis. Each stator segment can include a printed circuit board (PCB) having a PCB layer comprising a coil. Each stator segment also can include only one electrical phase. The stator itself can include one or more electrical phases.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 1/12 - Stationary parts of the magnetic circuit
• H02K 3/12 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 9/12 - Arrangements for cooling or ventilating by gaseous cooling medium flowing in closed circuit, a part of which is external to the machine casing wherein the cooling medium circulates freely within the casing
• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 1/27 - Rotor cores with permanent magnets
• H02K 3/47 - Air-gap windings, i.e. iron-free windings
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• H02K 1/32 - Rotating parts of the magnetic circuit with channels or ducts for flow of cooling medium
• H02K 16/00 - Machines with more than one rotor or stator
• H02P 31/00 - Arrangements for regulating or controlling electric motors not provided for in groups , or
• H02K 15/03 - Processes or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies having permanent magnets
• H02K 35/02 - Generators with reciprocating, oscillating or vibrating coil system, magnet, armature or other part of the magnetic circuit with moving magnets and stationary coil systems
• H02K 3/52 - Fastening salient pole windings or connections thereto

Abstract

A rotor element configured for movement relative to a stator includes a backing member formed, at least in part, from a ferromagnetic material; a first magnetic pole having a first polarity; and a second magnetic pole having a second polarity, opposite the first polarity. The first magnetic pole and the second magnetic pole are coupled to a first surface of the backing member such that the second magnetic pole is disposed, relative to the first magnetic pole, at a distance defined in a direction of a width of the backing member. A thickness of the backing member is varied along the width of the backing member to form a plurality of alternating first portions and second portions. The first portions include protrusions extending from a second surface of the backing member, opposite the first surface, such that the first portions are thicker than the second portions.

IPC Classes  ?

• H02K 41/02 - Linear motorsSectional motors
• H02K 1/27 - Rotor cores with permanent magnets

Abstract

An axial field rotary energy device (31) can include a rotor (33) having an axis (35) of rotation and a magnet (37). A stator (41) can be coaxial with the rotor. The stator can have a printed circuit board (PCB) (45) having a plurality of PCB layers (47) that are spaced apart in an axial direction. Each PCB layer can include a coil (49) having only two terminals (51, 53) for electrical connections. Each coil can be continuous and uninterrupted between its only two terminals. Each coil can consist of a single electrical phase. One of the two terminals of each coil can be electrically coupled to another coil with a via (55) to define a coil pair (57). Each coil pair can be electrically coupled to another coil pair with another via (59).

IPC Classes  ?

• H02K 1/22 - Rotating parts of the magnetic circuit
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 3/46 - Fastening of windings on the stator or rotor structure
• H02K 9/04 - Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium
• H02K 9/22 - Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
• H02K 11/33 - Drive circuits, e.g. power electronics
• H02K 15/08 - Forming windings by laying conductors into or around core parts
• H02K 17/04 - Asynchronous induction motors for single phase current
• H02K 17/12 - Asynchronous induction motors for multi-phase current
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Abstract

An axial field rotary energy device is disclosed. For example, the device can include a printed circuit board (PCB) stator having PCB panels. Each PCB panel can include conductive layers. Selected ones of the conductive layers can be coupled to plated vias that extend from one major surface of the PCB stator to an opposite major surface of the PCB stator. In addition, each major surface of the PCB stator can have a layer of a dielectric material that completely covers ends of the plated vies. Other embodiments of the axial field rotary energy device are disclosed.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H05K 1/16 - Printed circuits incorporating printed electric components, e.g. printed resistor, capacitor, inductor

Abstract

A system has an axial field rotary energy device with a housing, an axis and a rotor with a shaft, bearings, rotor disks and permanent magnets. A printed circuit board (PCB) stator is between the rotor disks to define an air gap on each side thereof. A variable frequency drive (VFD) assembly has a VFD housing and first pads coupled to inductors to facilitate heat removal from the inductors. A concave cradle is coupled to a ferromagnetic core and has a same contour as an outer surface of the ferromagnetic core. A second pad is coupled to a rectifier module. A third pad is coupled to switching devices and has pins to align the switching devices with the third pad. Standoffs are coupled to the VFD housing to support a first printed circuit board assembly (PCBA). A second PCBA is mounted to a shield plate above the first PCBA.

IPC Classes  ?

• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 5/02 - Casings or enclosures characterised by the material thereof
• H02K 5/04 - Casings or enclosures characterised by the shape, form or construction thereof
• H02K 7/08 - Structural association with bearings
• H02K 11/00 - Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
• H02K 11/30 - Structural association with control circuits or drive circuits
• H02K 11/33 - Drive circuits, e.g. power electronics

Abstract

A module (201) can be an axial field rotary energy device (31) including a housing (203) having coupling structures (209) configured to mechanically couple the housing to a second housing (203) of a second module (201). In addition, the housing can include electrical elements (204) configured to electrically couple the housing to the second housing. A rotor (233) can be rotatably mounted to the housing. The rotor can include an axis (235) and a magnet (237). A stator (241) can be mounted to the housing coaxially with the rotor. The stator can include a printed circuit board (PCB) (245) having a PCB layer (147) comprising a coil (149).

IPC Classes  ?

• H02K 1/22 - Rotating parts of the magnetic circuit
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 3/46 - Fastening of windings on the stator or rotor structure
• H02K 9/04 - Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium
• H02K 9/22 - Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
• H02K 11/33 - Drive circuits, e.g. power electronics
• H02K 15/08 - Forming windings by laying conductors into or around core parts
• H02K 17/04 - Asynchronous induction motors for single phase current
• H02K 17/12 - Asynchronous induction motors for multi-phase current
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Abstract

An axial field rotary energy device (31) can include a rotor (33) comprising an axis (35) of rotation and a magnet (37). In addition, a stator (141) can be coaxial with the rotor. The stator can include a plurality of stator segments (142) that are coupled together about the axis. Each stator segment can include a printed circuit board (PCB) (145) having a PCB layer (147) comprising a coil (149). Each stator segment also can include only one electrical phase. The stator itself can include one or more electrical phases.

IPC Classes  ?

• H02K 1/22 - Rotating parts of the magnetic circuit
• H02K 3/26 - Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• H02K 3/28 - Layout of windings or of connections between windings
• H02K 3/46 - Fastening of windings on the stator or rotor structure
• H02K 9/04 - Arrangements for cooling or ventilating by ambient air flowing through the machine having means for generating a flow of cooling medium
• H02K 9/22 - Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
• H02K 11/33 - Drive circuits, e.g. power electronics
• H02K 15/08 - Forming windings by laying conductors into or around core parts
• H02K 17/04 - Asynchronous induction motors for single phase current
• H02K 17/12 - Asynchronous induction motors for multi-phase current
• H02K 21/24 - Synchronous motors having permanent magnetsSynchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos

Abstract

An axial field rotary energy device or system includes an axis, a PCB stator and rotors having respective permanent magnets. The rotors rotate about the axis relative to the PCB stator. A variable frequency drive (VFD) having VFD components are coupled to the axial field rotary energy device. An enclosure contains the axial field rotary energy device and the VFD, such that the axial field rotary device and the VFD are integrated together within the enclosure. In addition, a cooling system is integrated with the enclosure to cool the axial field rotary energy device and the VFD.

IPC Classes  ?

• H02K 1/32 - Rotating parts of the magnetic circuit with channels or ducts for flow of cooling medium
• H02K 5/04 - Casings or enclosures characterised by the shape, form or construction thereof
• H02K 16/02 - Machines with one stator and two rotors

Abstract

A system can include an axial field rotary energy device with an axis of rotation and a rotor coaxial with the axis and having a shaft, bearings, rotor disks that are coaxial and permanent magnets on each rotor disk. A printed circuit board (PCB) stator is located between the rotor disks to define an air gap on each side of the PCB stator. An enclosure has two enclosure sections with an inspection port. Bearing caps and bearings are mounted to the rotor. A variable frequency drive (VFD) assembly is coupled to the axial field rotary energy device. The VFD has a flexible conduit that extends between the VFD housing and the axial field rotary energy device. The flexible conduit can adapt to different sizes of axial field rotary energy devices.

IPC Classes  ?

• H02K 1/18 - Means for mounting or fastening magnetic stationary parts on to, or to, the stator structures
• H02K 1/27 - Rotor cores with permanent magnets
• H02K 5/04 - Casings or enclosures characterised by the shape, form or construction thereof
• H02K 16/00 - Machines with more than one rotor or stator