Axial flux motor pole piece with conductive band

Abstract

Axial flux motors and related methods are disclosed herein. A disclosed axial flux motor includes a stator having a plurality of pole pieces, a rotor spaced apart from the stator in an axial direction of the axial flux motor, and a coiled tape of conductive material forming at least a portion of the pole pieces of the plurality of pole pieces. The axial direction of the coiled tape of conductive material is substantially parallel to the axial direction of the axial flux motor. In some embodiments of the disclosed axial flux motor, a coiled tape of soft magnetic material and a coiled tape of conductive material are coiled into staggered composite coils that form at least a portion of a pole piece for the axial flux motor.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Patent Application No. 18 / 241,159, filed on August 31, 2023, which claims the benefit of U.S. Provisional Patent Application No. 63 / 403,281, filed on September 1, 2022, the entire contents of which are incorporated herein by reference. Background Art

[0003] The axial flux motor was first patented by Niko la Tesla in U.S. Patent No. 405,858 in 1889. However, there was little room for commercial use of this machine until the invention of high-performance neodymium iron boron (Nd-Fe-B) permanent magnet material in 1983. Since then, the axial flux motor has rapidly gained widespread adoption due to its high efficiency and compactness compared to other technologies. The advent of environmentally friendly technologies such as electric vehicles has further enhanced the application space for axial flux motors. Today, axial flux motors are used in electric vehicles, robots of various sizes and types, and electric or hybrid propulsion systems for aircraft. It is generally desirable to reduce the power losses generated by the motor, thereby increasing the energy conversion efficiency of the motor. It is also desirable for the motor to be lightweight and compact, and to reduce its upfront manufacturing cost.

[0004] An axial flux machine generally includes a stationary component and a rotating component. In its most basic form, an axial flux machine includes at least three components: a stator, a rotor, and a rotor shaft. The stator is the stationary component, while the rotor and rotor shaft are the rotating components. An axial flux machine may also include more than one stator or more than one rotor. Figure 1 Two examples of axial flux machines are shown in the figures, wherein an axial section 100 shows an axial flux machine having one rotor and two stators, and an axial section 110 shows an axial flux machine having one stator and two rotors. A radial section 111 shows a stator in any axial flux machine. A radial section 112 shows a rotor in any axial flux machine. As used herein, the term radial section refers to a view obtained by observing the axial flux machine along the axis of the axial flux machine, and the term axial section refers to a view obtained by observing the axial flux machine along the radius of the rotor of the axial flux machine. The axial flux machine works by using a magnetic field in the direction of movement of the rotating part to exchange electrical energy and the rotational momentum of the rotating part.

[0005] The manner in which electrical energy and rotational momentum are exchanged in an axial flux motor depends on the specific design of the motor. With respect to axial flux motors, the design may include permanent magnets and controllably magnetized magnets. The permanent magnets may be on either the rotor or the stator, and the controllably magnetized magnets may be on either the rotor or the stator. The stator 101 and the rotor 102 may be, for example, Figure 1 The stator and rotor on two different types of axial flux electric machines are shown. In the example provided, the permanent magnets are on the rotor and the stator can be controllably magnetized to rotate the rotor. Additionally, in an alternative example, the permanent magnets are on the stator and the rotor can be controllably magnetized.

[0006] The controllably magnetizable magnet may include conductive coil windings and soft magnetic material. Figure 1 In the axial flux motor, the stator includes a coil winding 105, wherein the coil is made of a conductive material, and the terminals of the conductive coil are exposed to the outside to be powered by an external circuit. Typical conductive materials for the coil are aluminum and copper. Figure 1 As shown, the wire is wound around a trapezoidal pole piece 106 to form a coil winding 105. Such pole pieces are manufactured through a complex molding process using soft magnetic materials and laminations. The soft magnetic material allows the device to be magnetized under the influence of an electric current applied to the coil.

[0007] The rotor can be connected to the rotor shaft to transfer the rotor's rotational momentum to an external system. Figure 1 As shown, the rotor 102 may contain a circular array of permanent magnets 103 of alternating magnetic poles at specific intervals and is coupled to a rotor shaft 109. The rotor is typically supported by one or more bearings 108 that allow the rotor to rotate about an axis of rotation while maintaining a substantially uniform air gap between the rotor and the stator. Figure 1 In the example of the axial flux motor shown, when the coils of the stator are energized, the current flowing through the coils generates an alternating magnetic field between two adjacent coils with opposite polarities, and the magnetic flux generated by the coils repels or attracts the permanent magnets near them, thereby generating torque and rotating the rotor. The rotor shaft coupled to the rotor in turn transmits the torque to an externally connected load. Summary of the invention

[0008] Disclosed herein are electric machines for converting electrical energy into rotational mechanical energy or vice versa, and related methods and systems. The electric machine may be a permanent magnet synchronous AC machine in the form of an axial flux machine. The axial flux machine may be an electric motor or a generator.

[0009] Prior art axial flux motors have several disadvantages. For example, the motors do not take advantage of the flux carrying capacity of electrical steel and do not fully exploit the flux of the permanent magnets. Additionally, manufacturing the trapezoidal pole pieces, which are typically made from laminated electrical steel, is challenging because standard electrical steel stamping and joining methods are not easily accessible. Another possible way to address this challenge is to use soft magnetic composites, which are formed from soft magnetic materials such as iron or silicon steel, to sinter individual pole pieces into the desired shape and concentrate the permanent magnet flux of the rotor. However, the flux saturation levels achieved with soft magnetic composites are typically low.

[0010] In a specific embodiment of the present invention disclosed herein, a pole piece with a conductive strip is provided, which in a specific embodiment overcomes the shortcomings of the above-mentioned prior art methods and allows an alternative low-cost manufacturing process while significantly reducing motor losses.

[0011] In a specific embodiment of the present invention, an axial flux motor is provided. The axial flux motor includes a stator having a plurality of pole pieces, a rotor spaced apart from the stator in the axial direction of the axial flux motor, and a coiled strip made of a conductive material, the coiled strip of conductive material forming at least a portion of a pole piece among the plurality of pole pieces. The axial direction of the coiled strip of conductive material is substantially parallel to the axial direction of the axial flux motor. In some embodiments, the axial flux motor further includes a coiled strip made of a soft magnetic material, the coiled strip of soft magnetic material forming at least a portion of a pole piece. In these embodiments, the coiled strip of soft magnetic material and the coiled strip of conductive material can be wound together into a staggered composite material coil. In some embodiments, the axial flux motor further includes a coiled strip made of an insulating material, the coiled strip of insulating material forming at least a portion of a pole piece, wherein the coiled strip of soft magnetic material, the coiled strip of conductive material and the coiled strip of insulating material are wound together into a staggered composite material coil. In some embodiments, the conductive material is at least partially coated in the insulating material, so that the conductive material strip includes a conductive core, and when the conductive material is wound by itself or wound into a staggered composite material coil, it is insulated to prevent the conductive core from making ohmic contact. The sheath may surround the entire circumference of a section of the tape, or surround part of the way and cover only the top or bottom of a section of the tape.

[0012] In a specific embodiment of the present invention, an axial flux motor is provided. The axial flux motor comprises a stator having a plurality of pole pieces, a rotor spaced apart from the stator in the axial direction of the axial flux motor, and a conductive material coil, which forms at least a portion of a pole piece of the plurality of pole pieces. The conductive material coil forms a pole piece as an independent structure.

[0013] In a specific embodiment of the present invention, an axial flux motor is provided. The axial flux motor comprises a stator having a plurality of pole pieces, a rotor spaced apart from the stator in the axial direction of the axial flux motor, and a coiled strip made of a conductive material, the coiled strip of conductive material forming at least a portion of a pole piece of the plurality of pole pieces. The radial surface area of ​​the coiled strip forms at least half of the radial surface area of ​​the pole piece. As used herein, the term "radial surface area" refers to a surface measured perpendicular to the axial direction of the axial flux motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The accompanying drawings illustrate various embodiments of the system, method and various other aspects of the present disclosure. It will be appreciated by those of ordinary skill in the art that the element boundaries (e.g., boxes, box groups or other shapes) shown in the figures represent an example of boundaries. In some examples, an element may be designed as multiple elements, or multiple elements may be designed as one element. In some examples, an element shown as an internal component of an element may be implemented as an external component in another element, and vice versa. In addition, the element may not be drawn to scale. A non-restrictive and non-exhaustive description is made with reference to the following figures. The components in the figure are not necessarily drawn to scale, and emphasis is placed on illustrating the principle.

[0015] Figure 1 An axial flux motor according to the related art is shown.

[0016] Figure 2 An exploded view of an example of an axial flux electric machine according to a specific embodiment of the present invention is shown.

[0017] Figure 3 An example of a rotor according to a specific embodiment of the invention is shown.

[0018] Figure 4 An example of a stator according to a specific embodiment of the invention is shown.

[0019] Figure 5 An example of an interleaved composite coil according to a specific embodiment of the invention is shown.

[0020] Figure 6 An example of a piece of composite tape according to a specific embodiment of the invention is shown.

[0021] Figure 7 An enlarged view of an example of a corner of an interlaced composite coil is shown in accordance with a specific embodiment of the present invention.

[0022] Figure 8 A composite coil according to a specific embodiment of the present invention is shown.

[0023] Fig. 9 An example of a fully assembled pole piece having a first interlaced composite coil and a second interlaced composite coil according to a specific embodiment of the present invention is shown.

[0024] Fig.10 Shows Fig. 9 Exploded view of the assembled pole piece.

[0025] Fig.11 A process of forming folds in an interlaced composite coil according to a specific embodiment of the present invention is shown.

[0026] Fig.12A pole piece with a fold as an internal electrical connection according to a specific embodiment of the present invention is shown.

[0027] Fig.13 Folding for a composite coil according to a specific embodiment of the invention is shown.

[0028] Fig.14 A set of coil pairs with superimposable magnetic flux and external electrical connections according to a specific embodiment of the present invention is shown.

[0029] Fig.15 An example of a stator housing according to a specific embodiment of the present invention is shown.

[0030] Fig.16 Another example of a stator housing according to a specific embodiment of the present invention is shown.

[0031] Fig.17 A cross-sectional view of a completed assembly example of an axial flux electric machine according to a specific embodiment of the present invention is shown.

[0032] Fig.18 A cross-sectional view of an example of a fully assembled axial flux electric machine having a mechanical differential assembly according to a specific embodiment of the present invention is shown.

[0033] Fig.19 An example of gears of a mechanical differential assembly according to a specific embodiment of the present invention is shown.

[0034] Fig. 20 An example of a mechanical differential assembly according to a specific embodiment of the present invention is shown.

[0035] Fig.21 An example of an axially stacked axial flux machine according to a specific embodiment of the invention is shown. DETAILED DESCRIPTION

[0036] Reference will now be made in detail to implementations and embodiments of various aspects and variations of the systems and methods described herein. Although several exemplary variations of the systems and methods are described herein, other variations of the systems and methods may include various aspects of the systems and methods described herein, combined in any suitable manner, with combinations of all or some of the described aspects.

[0037] Methods and systems related to motors according to the above invention contents are disclosed in detail herein. The methods and systems disclosed in this section are non-limiting embodiments of the present invention and are used for explanation purposes only and should not be used to limit the full scope of the present invention. It should be understood that the disclosed embodiments may overlap with each other or may not overlap with each other. Therefore, an embodiment or a part of a specific embodiment thereof may or may not fall within the scope of another embodiment or a specific embodiment thereof, and vice versa. Different embodiments from different aspects may be combined or implemented separately. For those skilled in the art, many obvious different combinations and sub-combinations of the representative embodiments shown within the broad framework of the present invention, although not explicitly shown or described, should not be interpreted as being excluded.

[0038] Figure 2 An exploded view of an axial flux machine 200 (hereinafter, the axial flux machine is generally referred to as a machine or a machine) according to a specific embodiment of the present invention is shown. The machine has a stator 201 and two rotors 202, 203, such that one rotor is located on one side of the stator and the other rotor is located on the opposite side of the stator. The stator and the rotor are axially positioned along the axis of rotation of the rotor. The rotor is adjacent to the stator, but there is a gap between them. When assembled, the rotor is spaced apart from the stator in the axial direction of the axial flux machine to form the gap. For example, the spacing between the stator and the rotor can be between 0.1 mm and 3 mm. The machine includes an external support structure in the form of a housing, which includes housing parts 204, 205, a rotor shaft 208 and rotor support bearings 206, 207. When assembled, the rotor shaft is fixedly connected to each of the two rotors 202, 203. The bearings 206, 207 are in turn supported by the stator housing. The bearings 206, 207 allow the rotor shaft to rotate relative to the stator, which is stationary as described above. The stator comprises stator electrical contact terminals 211, 212, 213 for supplying current to the stator from an external power source. Each rotor 202, 203 comprises a permanent magnet disk 209, 210 on the side of the rotor facing the stator 201 .

[0039] In specific embodiments of the present invention, the axial flux motor may include only one rotor and one stator. In other embodiments of the present invention, the axial flux motor may include only one rotor and two stators, such that one stator is on one side of the rotor and the other stator is on the opposite side of the rotor. In alternative embodiments, the axial flux motor may include more rotors and stators that apply torque on a common rotor shaft. In specific embodiments of the present invention, two rotors driven by a single stator can distribute torque to two independent rotor shafts. In specific embodiments, the two rotors driven by a single stator can be connected to a mechanical differential assembly so that they apply torque on a common rotor shaft having two parts, so that the two parts can also rotate independently of each other. In some embodiments, the rotor shaft is hollow.

[0040] Figure 3 300 according to one embodiment of the present invention is shown. A permanent magnetic disk 301 is attached to a rotor support structure 302 which provides mechanical support for the disk. The permanent magnetic disk 301 is magnetized to produce Figure 3 The substantially axial magnetic field with alternating north (N) and south (S) magnetic poles is shown. In another embodiment, the permanent magnetic disk 301 is implemented by connecting multiple permanent magnets together or connecting multiple permanent magnets to the rotor support structure 302. In either embodiment, the permanent magnets do not have to be as Figure 3 The rotor support structure of each rotor is in turn attached to Figure 2 The rotor shaft 208 in the embodiment of the present invention is connected in a manner that allows the transmission of torque without relative motion at the contact surfaces between the rotor shaft and the rotor support structure, and all parts of the rotor rotate around at the same speed. Figure 2 The bearings 206 and 207 rotate about an axis defined by the support bearings 206 and 207.

[0041] Figure 4 A stator 400 according to a specific embodiment of the present invention is shown. The stator 400 includes a plurality of stator electrical contact terminals 402, 403, 404. The stator also includes a plurality of pole pieces, such as pole piece 401. In this example, each pole piece includes two interlaced composite coils (in Figure 4 For each pole piece, a second interlaced composite coil is adjacent to the interlaced composite coil shown in the axial direction, so that Figure 4 Hidden in.

[0042] In specific embodiments, each pole piece may include only one staggered composite coil or include multiple staggered composite coils. As described below, in some embodiments, each pole piece may include multiple staggered composite coils, including adjacent coils that are wound in the same direction and wound from the outside of the coil to the inside of the coil, and adjacent coils that are wound in the same direction and wound from the inside of the coil to the outside of the coil. As used herein, the term "direction" when used with reference to the winding direction can be a counterclockwise direction or a clockwise direction relative to a fixed reference plane. As used herein, the term "inward" can refer to the coil being wound from the outside of the coil to the inside, while "outward" can refer to the coil being wound from the inside of the coil to the outside. Therefore, the conductive tape and the wound staggered composite coil disclosed herein will each generate a magnetic flux in the axial direction of the axial flux motor, and this magnetic flux is added to the magnetic flux of other coils wound in the same direction. It is worth noting that the tape wound inward counterclockwise will generate the same magnetic flux as the tape wound outward counterclockwise. In this way, in Figure 4 The interlaced composite coil shown as part of pole piece 401 and the second interlaced composite coil forming part of pole piece 401 will produce superimposable magnetic flux in an axial direction relative to stator 400 because they are both wound in the same direction.

[0043] Figure 5 An interlaced composite coil 500 according to a specific embodiment of the present invention is shown. The interlaced composite coil 500 is formed by winding a composite tape 501 inwardly counterclockwise (i.e., counterclockwise from the outside of the coil to the inside of the coil). When installed, the axial direction of the interlaced composite coil will be substantially parallel to the axial direction of the axial flux motor. Figure 6 FIG. 6 shows a composite material strip 600 according to an embodiment of the present invention. The composite material strip 600 is sequentially Figure 6 The soft magnetic material strip 601, the insulating material strip 602, the conductive material strip 603 and the second insulating material strip 604 are arranged alternately from the right side to the left side, and there is an insulating material strip on each side of the conductive material strip. The material of the soft magnetic material strip can be iron, silicon steel, magnetic cobalt alloy, amorphous steel or any other suitable material. The material used for the conductive material strip can be copper, aluminum or any other suitable material. The insulating material can be a part of the conductive material strip, or a part of the soft magnetic material strip, or a part of the conductive material strip and the soft magnetic material strip, rather than a separate material strip. The insulating material can be part of the strip because it covers at least a portion of the conductive material or the soft magnetic material. The sheath can be partial because the end needs to be ohmically connected to the bias voltage source. However, inside the coil, all sides of the strip can be covered with insulating material. The cross section can be Figure 6 The same is shown with an optional additional layer of insulating material along the exposed side of the strip of soft magnetic material 601 shown.

[0044] like Figure 6 As shown, each strip of a particular material has two straight cross-sectional sides, where W is the width of the strip measured in the axial direction of the interlaced composite coil 500, and T is the thickness of the strip measured in the radial direction of the interlaced composite coil 500. The composite strip may include multiple strips of the same material. For example, two strips of conductive material may be pressed together in the composite strip. This has the beneficial effect of doubling the thickness of the conductive material and reducing the ohmic resistance of the conductive material by half (assuming all other factors remain constant). This is particularly beneficial because during operation, when the interlaced composite coil is energized, the magnetic poles of its magnetic flux alternate, and the lower the resistance through the conductive material, the faster the magnetic pole change rate. In this way, the thickness of the coiled strip of conductive material and the performance of the axial flux machine can be easily adjusted: the greater the thickness of the strip, the lower the resistance and the faster the magnetic pole switching rate; conversely, the smaller the thickness of the strip, the higher the resistance and the slower the magnetic pole switching rate. However, increasing the thickness of the coiled conductive material strip in this way increases the weight of the machine and increases the manufacturing cost. These principles also apply to the width W of the strip. The designed thickness of the belt may be appropriately determined after weighing weight, manufacturing cost, and performance.

[0045] Figure 7 70 is an enlarged view of a corner of an interlaced composite coil according to a specific embodiment of the present invention. Because the interlaced composite coil is formed by winding a composite tape, the interlaced composite coil includes a soft magnetic material coil 701, an insulating material coil 702, a conductive material coil 703, and a second insulating material coil 704, which are wound together to form an interlaced composite coil. Adjacent turns of the interlaced composite coil are separated by an air gap 705. The coiled tape can be formed Figure 4 A portion of the middle electrode 401.

[0046] In a specific embodiment, the interlaced composite coil 500 may not include any insulating material winding tape. For example, the conductive material tape, and the conductive material winding tape after winding, may be coated with an electrically insulating film or coated with an insulating material. Optionally, the various tapes in the interlaced composite coil 500 may each be separated by an air gap rather than by an insulating material. In some embodiments, the composite tape 600 may not include any soft magnetic material tape, and therefore, the interlaced composite coil may not include any soft magnetic material winding tape. In a specific embodiment, the conductive material winding tape and at least one other conductive material winding tape are pressed together and wound together into a composite conductive coil, in which case the interlaced composite coil includes a composite conductive coil.

[0047] In a specific embodiment, since the axial direction of the interlaced composite coil is substantially parallel to the axial direction of the axial flux machine, the axial direction of each component winding strip of the interlaced composite coil is substantially parallel to the axial direction of the axial flux machine. Figure 7 In the illustrated embodiment, the axial direction of the coiled strip of conductive material 703 is substantially parallel to the axial direction of the axial flux motor. The coiled strip of conductive material forms a set of windings, and an air gap 705 separates adjacent windings in the set of windings. As shown, the coiled strip of conductive material forms at least two complete concentric turns.

[0048] In a specific embodiment of the present invention, the coiled strip of conductive material is integrally formed Figure 4 This is in contrast to the related art axial flux motor discussed above, as the conductive material is not coiled around a central structure (e.g., Figure 1 106). Thus, the present invention does not require the complex manufacturing processes that accompany the construction of such a central structure. In addition, the strip of conductive material can be coiled into coils of any geometric shape, including, for example, rectangular, circular, triangular, pie-shaped, pentagonal, etc. This provides certain benefits because the pole pieces can be formed into different geometries required to fit alternative design constraints of axial flux machines. In a specific embodiment, the profile of the coiled strip of conductive material is formed as follows Figure 5 Furthermore, using these methods, the soft magnetic material (if present) can be distributed over the entire surface area of ​​the pole piece, rather than just in the center of the pole piece, while leaving space for external windings, such as Figure 1 , as shown in the pole piece 106 in. In a specific embodiment, the ring defined by the innermost ring of the coiled strip of conductive material and the outermost ring of the coiled strip of conductive material forms at least half of the surface area of ​​the pole piece measured in the radial direction of the axial flux motor. In this way, the coiled strip of conductive material and any soft magnetic material in the same interlaced composite coil can be distributed over the entire surface area of ​​the pole piece. The distribution of soft magnetic material over a larger portion of the pole piece can improve the efficiency of the motor. In a specific embodiment, the diameter of the coiled strip of conductive material is at least half of the surface area of ​​the pole piece measured in the radial direction of the coiled strip of conductive material. In a specific embodiment, the radial surface area of ​​the coiled strip of conductive material forms at least half of the radial surface area of ​​the pole piece. Figure 5 An interleaved composite coil is shown whose radial surface area is the entire radial surface area of ​​the pole piece, as the entire pole piece is defined by the interleaved composite coil.

[0049] In a specific embodiment of the present invention, a coil of conductive material forms a pole piece as a stand-alone structure. In a specific embodiment of the present invention, a coil of interlaced composite material forms a pole piece as a stand-alone structure. In this way, the pole piece does not require a substrate, except for the material strip that forms the pole piece. For example, the interlaced composite material coil 500 can be used as a stand-alone structure, because the coiled strip itself is the pole piece, and they do not require a substrate to support it. Therefore, the pole piece formed according to the specific embodiment of the present invention disclosed herein is not limited by compatibility with any substrate in terms of the type of material that can be used to form the pole piece. In addition, the thickness and width of the strip are not limited by compatibility with what is supported by a given substrate. This increased flexibility represents a significant improvement over related art methods.

[0050] refer to Figure 5 According to a specific embodiment, the interlaced composite coil 500 has two ends: an outer coil end at the periphery of its outermost turns and an inner coil end at the center of its innermost turns. The coiled strip of conductive material in the interlaced composite coil has an external electrical contact terminal 503 at the outer coil end and an internal electrical contact terminal 502 at the second end. For a coil wound counterclockwise outward from the center of the coil, the bending direction toward the external electrical contact will be in the opposite direction.

[0051] In a specific embodiment, the coiled strip of conductive material includes at least two straight edges. For example, Figure 5 The interleaved composite coil 500 in comprises a coiled strip of conductive material formed to have two straight sides, wherein the straight sides are intended to engage radial segments of a stator housing.

[0052] In specific embodiments, the belts disclosed herein can have various sizes. For example, when measured in the radial direction of the coiled belt of conductive material, the thickness of the coiled belt of conductive material is less than 1 mm. In some embodiments, the width of the coiled belt of conductive material measured in the axial direction of the coiled belt is at least 1 mm. In specific embodiments, the dimensions of any coiled belt of soft magnetic material coiled together with the coiled belt of conductive material have similar measurements. In some embodiments, there is a significant difference between the thickness of the coiled belt of soft magnetic material measured in the radial direction of the coiled belt of soft magnetic material and the thickness of the coiled belt of conductive material measured in the radial direction of the coiled belt of conductive material. As previously described, the size of the belt can be increased to reduce the resistance of the belt, or it can be reduced to reduce the weight of the axial flux motor. In addition, the width of the conductive belt can be kept small to reduce the effects of eddy currents.

[0053] Figure 8 A composite interlaced composite coil 800 consisting of an interlaced composite coil 801 and a second interlaced composite coil 802 is shown for explaining a specific embodiment of the present invention. Figure 8The two interleaved composite coils shown in can have similar properties to the interleaved composite coil 500. For example, the interleaved composite coil 801 can include a coiled strip of conductive material, and the second interleaved composite coil 803 can include a second coiled strip made of conductive material. As shown, the coiled strip of conductive material that is part of the interleaved composite coil 801 is coiled in a first direction (i.e., counterclockwise), and the second coiled strip of conductive material that is part of the second interleaved composite coil 803 is also coiled in the first direction (i.e., counterclockwise). In addition, the second coiled strip of conductive material and the coiled strip of conductive material are adjacent in the axial direction of the axial flux motor. Due to this structure, the axial flux of each coiled strip of conductive material will be added. In addition, the method shown produces significant benefits: the combined conductivity of the two coils will be equal, resulting in higher switching speeds, while the width of each individual strip is reduced by half compared to a single coil with the same conductivity. This is important because wider strips will generate eddy currents, which in turn reduce the switching speed and efficiency of the pole pieces. In the example Figure 8 In the combined interlaced composite coil shown, the number of independent coiled strips can be increased to more than two to increase the benefit of this effect. At the same time, an insulating adhesive can be used to adhere the strips to adjacent strips so that the composite coil still maintains a structural cumulative width sufficient to be used as a stand-alone structure. In the case shown, the width of the second coiled strip of conductive material and the coiled strip of conductive material are both less than 5 cm when measured in the axial direction of the axial flux machine. In a specific embodiment of the present invention, the number of coiled strips of conductive material can be increased to the extent that the coiled strips of conductive material replace the single strand of conductive material in the Litz wire.

[0054] Fig. 9 An example of an assembled pole piece 900 having a first interlaced composite coil 901 and a second interlaced composite coil 902 according to a specific embodiment of the present invention is shown. The interlaced composite coil may include a coiled strip of conductive material. In a specific embodiment, each interlaced composite coil has an external electrical contact terminal and an internal electrical contact terminal. Depending on the configuration of the axial motor, the external electrical contact terminal may be a positive contact terminal or a negative contact terminal. In addition, the internal electrical contact terminals of different interlaced composite coils may be coupled together. Fig. 9 In the specific configuration shown, the internal electrical contacts of the two coils can be coupled together, and one of the external electrical contact terminals can be a positive contact terminal, while the other external electrical contact terminal is a negative contact terminal. As shown, the first interlaced composite coil 901 is wound clockwise inward, and the second interlaced composite coil 902 is wound clockwise outward. Therefore, the two adjacent coils produce a superimposable magnetic flux and also form a continuous circuit from the positive contact terminal to the negative contact terminal, both of which are located outside the stator, and the assembled pole piece 900 will be installed in the stator.

[0055] Fig.10 An exploded view 1000 of the assembled pole piece 900 is shown. The exploded view shows two interlaced composite coils, each of which is broken down into two main material coils, for a total of four coils. The first interlaced composite coil 1001 has an external electrical contact terminal 1003 and an internal electrical contact terminal 1004 on a coiled tape of conductive material as part of the composite coil. The second interlaced composite coil 1002 has an external electrical contact terminal 1005 and an internal electrical contact terminal 1006 on a coiled tape of conductive material as part of the composite coil. The internal electrical contact terminal 1004 and the internal electrical contact terminal 1006 are each electrically connected to a conductive pin 1007. The conductive pin 1007 contacts the innermost circle of the coiled tape and the innermost circle of the second coiled tape, and forms a portion of a conductive path between the two external contact terminals. In this way, the external electrical contact terminal 1003 of the first interlaced composite coil 1001 is ohmically connected to the external electrical contact terminal 1005 of the second interlaced composite coil 1002, forming a conductive path between the two external electrical contact terminals.

[0056] The connections between the axially spaced individual coils of conductive material in an axial electric machine can be provided in various ways. Fig. 9 and Fig.10 In the example of , the connection is provided by a conductive pin. In other embodiments, the conductive path between the two external electrical contact terminals is formed in different ways. For example, in an alternative embodiment, a single strip of conductive material can form the two coils as an integral single piece. Thus, an interlaced composite coil having such a single strip of conductive material can be coiled inwardly from the first external electrical contact terminal toward the center of the pole piece in a first plane, bend from the first plane where the first coil is located to the second plane where the second coil is located, and then be coiled outwardly from the center of the pole piece to the second external electrical contact terminal in the second plane. In other words, the coiled strip of conductive material in the first interlaced composite coil (e.g., 1008) and the second coiled strip of conductive material in the second interlaced composite coil (e.g., 1009) can be part of a single continuous strip of conductive material. The following reference can be made to the following. Fig.11 The described process folds a single continuous strip of conductive material. Thus, in particular embodiments, the conductive path between the axially spaced coils may include a fold in the single continuous strip of conductive material that connects a coiled strip of conductive material and a second coiled strip of conductive material.

[0057] Fig.11A process of forming an internal connection in a single continuous strip of conductive material in a folded form is shown. In step 1100, a single continuous strip of conductive material can be provided. As shown, the material strip can be folded in step 1101 so that the folded portion forms a right triangle profile with the top surface of the unfolded original material strip. Next, in step 1102, the folded portion can be folded again so that the material strip is oriented in the same direction on both sides of the fold. In step 1102, the folding position can be selected so that there is enough offset between the plane occupied by the original unbent side of the material strip and the plane occupied by the bent side of the material strip, so that the two occupied planes have enough spacing for the coils to form pole pieces. Since the material strip is oriented in the same direction on either side of the fold, the coils formed on both sides of the fold will be wound in the same direction and their magnetic fluxes will be added.

[0058] Fig.12 Shows the use of Fig.11 The pole piece 1201 formed by the method shown in the figure, the two interlaced composite material coils are formed by a single continuous strip of conductive material and a single continuous strip of soft magnetic material, and the two material strips are formed according to Fig.11 As shown, the pole piece includes two external electrical contacts, and the two coils are oriented so that their magnetic fluxes are additive (ie, both coils are coiled counterclockwise, with coil 1202 coiled inwardly and coil 1203 coiled outwardly).

[0059] Fig.13 shows a folding pattern that allows a composite coil to be used with reference Fig.11 and Fig.12 The folded form of the internal electrical connection. The composite coil can be reference Figure 8 The composite coil described herein may include an internal connection for connecting to another composite coil, wherein the orientation of the two composite coils is the same as that of the reference Fig. 9 and Fig.10 1300 shows a top view of the fold and view 1310 shows a bottom view of the fold. As shown, two single strips of conductive material and two single strips of soft magnetic material are folded to form a composite coil and then transferred to a different plane to form a second composite coil. Since the material strips are oriented in the same direction on either side of the fold, the two composite coils will be wound in the same direction and have superimposable magnetic flux. At the same time, one composite coil can be wound inwardly and the other composite coil can be wound outwardly so that the pole piece formed by the two composite coils can have two external electrical connections.

[0060] Fig.14A set of coil pairs is shown, arranged so that all coils have superimposable magnetic flux, and each pair of coils forms a single conductive path into the center of the coil and back to the outside of the coil, thereby presenting positive and negative contact terminals on the outside of the coil. According to the present disclosure, the set of coil pairs can form pole pieces of an axial flux motor. Although Fig.14 Two pairs of coils are included, illustrated by coil pair 1400 and coil pair 1410, but a set of coil pairs according to the present disclosure may include any number of coil pairs, as long as the pattern shown is continuous. For example, a set of coil pairs forming a pole piece may include 2, 3, or 4 pairs of coils. A single coil in a coil pair may also be a reference Figure 8 The composite coil.

[0061] Fig.14 The illustrated pattern includes a coiled strip of conductive material coiled inwardly in a first direction and at least one additional coiled strip of conductive material coiled in the first direction (e.g., an outer coil of coil pair 1400 and an outer coil of coil pair 1410), and a second coiled strip of conductive material coiled in a second direction and at least one additional coiled strip of conductive material coiled in the second direction (e.g., an inner coil of coil pair 1400 and an inner coil of coil pair 1410), wherein the at least one additional coiled strip of conductive material coiled in the first direction and the at least one additional coiled strip of conductive material coiled in the second direction are arranged adjacent in an axial direction of the axial flux motor such that the magnetic flux of the coiled strip of conductive material, the second coiled strip of conductive material, the at least one additional coiled strip of conductive material coiled in the first direction, and the at least one additional coiled strip of conductive material coiled in the second direction are additive. Patterns according to the present disclosure may also be described with reference to the inward or outward winding of the coils and the direction of the coils. In this pattern, each coil will be wound in the same direction, with the A coils winding inward and the B coils winding outward and vice versa. Thus, the pattern will be AB-BA-AB-BA, where the pattern will continue as many times as needed to form the pole pieces within the constraints of the overall axial machine (such as minimizing the weight and other constraints of the axial flux machine).

[0062] In a specific embodiment of the invention, the axial flux motor comprises a first pair of coiled strips of conductive material. Fig. 9The described coiled strips of conductive material and the second coiled strips of conductive material can form a first pair of coiled strips of conductive material. The first pair of coiled strips of conductive material can be coiled strips of coil pair 1400. The axial flux motor may include at least one additional pair of coiled strips of conductive material, such as coil pair 1410, wherein the at least one additional pair of coiled strips of conductive material and the first pair of coiled strips of conductive material form a group of coiled strip pairs of conductive material. As shown, each coiled strip of conductive material in the group of coiled strip pairs of conductive material is coiled in a first direction, each pair of coiled strips of conductive material in the group of coiled strip pairs of conductive material has a coil wound inwardly and a coil wound outwardly, and the group of coiled strip pairs of conductive material are arranged adjacent to each other in the axial direction of the axial flux motor, so that a pair of coils wound inwardly is never adjacent to another pair of coils wound outwardly. Using this method, the magnetic flux of the coils is added, and each pair of coils provides two external electrical contacts. The coil pairs can share a common conductive connection at their internal contacts, such as a common conductive pin.

[0063] Fig.15 An example of a stator housing 1500 for assembling and housing pole pieces in a stator according to a specific embodiment of the invention is shown. The stator housing comprises a set of pole piece compartments 1501 . Fig.15 The shape of the pole piece compartments in is not a limitation of the embodiments of the invention disclosed herein. In fact, the benefit of using the specific embodiments of the invention disclosed herein is that the strip can be formed to form pole pieces of widely varying sizes so that they can accommodate arrays of different pole piece compartment designs. In other embodiments, the stator housing can be formed by connecting the first stator housing 1601 and the second stator housing 1602 together, such as Fig.16 As shown. The stator housing can be made of various parts mainly made of metal, polymer or composite materials and mechanically connected together by known connection methods (such as bonding, fasteners, rivets or others). The pole pieces are attached to the stator housing and installed in the pole piece compartments: one pole piece is installed in one pole piece compartment. Figure 4 A view of one side of the stator shows the pole pieces being assembled in this way. In a particular embodiment, the stator housing is overmolded onto the pole pieces.

[0064] As combined Fig. 9 As discussed, each assembled pole piece 900 includes two interlaced composite coils 901, 902. In a specific embodiment, each pole piece is electrically connected to a conductive busbar not shown in the figure through two external electrical contact terminals 1003, 1005 of the pole piece. In this way, all pole pieces of the stator are connected through the busbar. In turn, the busbar is electrically connected to the electrical contact terminals 402, 403, 404 of the stator. In some embodiments, some or all of the external electrical contact terminals of the pole pieces, or the electrical contact terminals of the stator are arranged along the outer diameter of the stator. For example, in Figure 4In some embodiments, the electrical contact terminals of the stator are arranged along the outer diameter of the stator. In some embodiments, some or all of the outer electrical contact terminals of the pole pieces, or the electrical contact terminals of the stator are arranged along the inner diameter of the stator.

[0065] In the pole piece assembled in the stator as described above, the first interlaced composite coil 901 and the second interlaced composite coil 902 of the pole piece are separated by a small gap, which ensures that the conductive coils maintain a minimum distance to avoid any air electrical breakdown due to the potential generated during operation. Alternatively, the gap is filled with dielectric oil, which can enhance the dielectric strength of the gap and allow a narrower gap. Alternatively, the dielectric oil flows through the gap, allowing heat to be transferred from the coil to an external radiator. This is achieved by connecting the oil flow path to a pump, which keeps the dielectric oil flowing in the gap between the first interlaced composite coil 901 and the second interlaced composite coil 902.

[0066] Fig.17 Shows Figure 2 A cross-sectional view of an axial flux electric machine in which the various components of the electric machine as described above have been assembled. Fig.17 Shown are a rotor support structure 1701 and a permanent magnet disk 1702 of a first rotor portion on one side of the stator, a rotor support structure 1703 and a permanent magnet disk 1704 of a second rotor portion on the other side of the stator opposite the first rotor portion, a pole piece 1705, a rotor shaft 1706, rotor support bearings 1707, 1708 and a housing including housing parts 1709, 1710. The stator is fixed to the housing by a stator support structure 1711. The similarly shaded portion above the rotor shaft 1706 of the axial flux machine is an alternative component of the same circular component.

[0067] Fig.18 A cross-sectional view of a specific embodiment of an axial flux electric machine is shown, which includes a first rotor shaft 1801, a second rotor shaft 1802, and a mechanical differential assembly 1803. The mechanical differential assembly transfers torque from the rotor to the rotor shafts and allows a rotational difference between the two rotor shafts using gears, pinions, and other components. Allowing for a rotational difference allows the two rotor shafts to perform relative rotational motion. Fig.19 An example of a gear of a mechanical differential assembly having two shafts 1901, 1902 and associated gears is shown. Fig.18 In the embodiment, the mechanical differential assembly is located inside the axial flux electric machine. In an alternative embodiment, the mechanical differential assembly can be located outside the machine. In such an embodiment, Fig. 20As shown, the rotor is coupled to a hollow main rotor shaft 2001, the differential assembly 2002 is located directly outside the axial flux machine, and one of the rotor shafts passes through the hollow main shaft from one side of the machine to the differential assembly located on the other side of the machine. The differential assembly 1502 transfers torque from the main rotor shaft to a first rotor shaft 1503 and a second rotor shaft 1504, the first rotor shaft 1503 passing through the hollow main shaft, but using gears and pinions and other components to cause a rotational difference between the two rotor shafts.

[0068] In a specific embodiment of the present invention, two or more axial flux motors as described above can be axially stacked and form a single motor assembly. The two motors can be connected to a common rotor shaft or to different rotor shafts. Fig.21 An axial flux machine is shown having two axial flux machines 2100, 2110 forming a single machine assembly. The machine assembly includes two stators, each stator including a plurality of composite coils 2101, and a rotor having permanent magnets 2102. The two rotors are connected to a rotor shaft 2103 via a rotor support 2104. In alternative embodiments, the two rotors may be connected to different rotor shafts. In the illustrated embodiment, the two stators may be electrically connected, or they may be powered by completely separate circuits.

[0069] Although the present specification has described the specific embodiments of the present invention in detail, it is to be understood that those skilled in the art can easily conceive of modifications, variations and equivalents of these embodiments after understanding the above content. These and other modifications and variations of the present invention can be implemented by those skilled in the art without departing from the scope of the present invention, and the scope of the present invention is more specifically described in the appended claims.

[0070] Although this specification has described specific embodiments of the present invention in detail, it is to be understood that those skilled in the art, after understanding the above, can easily conceive of modifications, changes and equivalents of these embodiments. Although the examples in the present disclosure generally relate to axial flux motors in the form of axial flux motors, the embodiments disclosed herein are also applicable to axial flux generators. As another example, the composite coils disclosed herein can be used to replace any single coil described herein. In addition, wherever interlaced composite coils are mentioned, independent conductive material sheath strips can be used instead. These and other modifications and variations of the present invention can be implemented by those skilled in the art without departing from the scope of the present invention, and the scope of the present invention is more specifically set forth in the appended claims.

Claims

1. An axial flux motor, comprising: A stator (101, 400), wherein the stator (101, 400) has a plurality of pole pieces; a rotor (102, 300), the rotor (102, 300) being spaced apart from the stator (101, 400) in the axial direction of the axial flux motor; and a coiled strip (603, 703) of conductive material, the coiled strip (603, 703) of conductive material forming at least a portion of a pole piece (1201, 1705) of a plurality of pole pieces; Wherein, the axial direction of the conductive material winding belt (603, 703) is substantially parallel to the axial direction of the axial flux motor.

2. The axial flux motor according to claim 1 , further comprising: A coiled strip (601, 701) of soft magnetic material, the coiled strip (601, 701) of soft magnetic material forming at least a portion of a pole piece; The soft magnetic material coiled strips (601, 701) and the conductive material coiled strips (603, 703) are coiled together to form an interlaced composite material coil (500).

3. The axial flux motor according to claim 2, wherein: The material of the conductive material coiled tape (603, 703) is at least one of copper and aluminum; and The material of the soft magnetic material coiled strip (601, 701) is at least one of iron, silicon steel, soft magnetic cobalt alloy and amorphous steel.

4. The axial flux motor according to claim 2, wherein: The interlaced composite coil (500) forms a pole piece as a stand-alone structure.

5. The axial flux electric machine according to claim 2, further comprising: a coiled strip (602, 702) of insulating material, the coiled strip (602, 702) of insulating material forming at least a portion of a pole piece; The soft magnetic material coiled tape (601, 701), the conductive material coiled tape (603, 703) and the insulating material coiled tape (602, 702) are coiled together to form the interlaced composite material coil (500).

6. The axial flux motor according to claim 1, wherein: The coiled strip (603, 703) of conductive material is at least partially encased in insulating material.

7. The axial flux electric machine according to claim 1, further comprising: a second coiled strip (603, 703) of conductive material, the second coiled strip (603, 703) of conductive material forming at least a portion of a pole piece; Wherein, (i) the coiled strip (603, 703) of conductive material is coiled along a first direction; (ii) the second coiled strip (603, 703) of conductive material is coiled along the first direction; (iii) the second coiled strip (603, 703) of conductive material and the coiled strip (603, 703) of conductive material are adjacent in the axial direction of the axial flux motor; and (iv) the width of the second coiled strip (603, 703) of conductive material and the coiled strip (603, 703) of conductive material measured in the axial direction of the axial flux motor is less than 5 cm.

8. The axial flux motor according to claim 1, wherein: The coiled strip (603, 703) of conductive material comprises at least two straight sides.

9. The axial flux motor according to claim 1, wherein: The contour of the coiled strip (603, 703) of conductive material forms a polygon.

10. The axial flux electric machine according to claim 1, wherein: The coiled strip (603, 703) of conductive material forms at least two complete concentric circles.

11. The axial flux electric machine according to claim 1, wherein: The annular area defined by the innermost turn of the coiled strip (603, 703) of conductive material and the outermost turn of the coiled strip (603, 703) of conductive material forms at least half of the radial surface area of ​​the pole piece.

12. The axial flux electric machine of claim 1 , further comprising: A coiled strip (601, 701) of soft magnetic material, the coiled strip (601, 701) of soft magnetic material forming at least a portion of a pole piece; Wherein, (i) the soft magnetic material coiled strips (601, 701) and the conductive material coiled strips (603, 703) are wound together to form the interlaced composite coil (500); and (ii) the annular area defined by the innermost circle of the interlaced composite coil (500) and the outermost circle of the interlaced composite coil (500) includes at least half of the surface area of ​​the pole piece in the radial direction of the axial flux motor.

13. The axial flux electric machine according to claim 1, wherein: The diameter of the coiled strip of conductive material (603, 703) measured in the radial direction of the coiled strip of conductive material (603, 703) is at least half of the surface area of ​​the pole piece in the radial direction of the axial flux motor; and The thickness of the coiled strip of conductive material (603, 703) is less than 1 mm, measured along the radial direction of the coiled strip of conductive material (603, 703).

14. The axial flux electric machine according to claim 1, wherein: The coiled strip (603, 703) of conductive material forms a pole piece as a separate structure.

15. The axial flux electric machine according to claim 14, further comprising: A stator (101, 400) housing having a set of pole piece compartments (1501); Wherein, the pole piece is attached to the stator (101, 400) housing and installed in one compartment of the set of pole piece compartments (1501).

16. The axial flux electric machine according to claim 1, wherein: The width of the coiled strip of conductive material (603, 703) measured in the axial direction of the coiled strip of conductive material (603, 703) is at least 1 mm.

17. The axial flux electric machine according to claim 16, wherein: The thickness of the coiled strip of conductive material (603, 703) measured in a radial direction along the coiled strip of conductive material (603, 703) is less than 1 mm.

18. The axial flux electric machine of claim 1 , further comprising: a second coiled strip (603, 703) of conductive material, the second coiled strip (603, 703) of conductive material forming at least a portion of a pole piece; Wherein: (i) the coiled tape (603, 703) of conductive material provides a first external electrical contact for the pole piece on the outermost circle of the coiled tape; (ii) the second coiled tape (603, 703) of conductive material provides a second external electrical contact for the pole piece on the outermost circle of the second coiled tape; and (iii) the first external electrical contact is ohmically coupled to the second external electrical contact via a conductive path through the coiled tape and the second coiled tape.

19. The axial flux electric machine of claim 18, further comprising: A conductive pin (1007) contacts the innermost turn of the coiled tape and the innermost turn of the second coiled tape and forms a portion of the conductive path.

20. The axial flux electric machine of claim 18, further comprising: a single strip of conductive material forming said coiled strip of conductive material (603, 703) and said second coiled strip of conductive material (603, 703); and A fold in the single strip of conductive material, the fold forming a portion of the conductive path.

21. The axial flux electric machine according to claim 18, wherein: The coiled strip of conductive material (603, 703) and the second coiled strip of conductive material (603, 703) are part of a single continuous strip of conductive material; and The conductive path comprises a fold in the single continuous strip of conductive material, the fold connecting the coiled strip of conductive material (603, 703) and the second coiled strip of conductive material (603, 703).

22. The axial flux electric machine of claim 1 further comprising: a first pair of coiled strips of conductive material, wherein the coiled strip of conductive material (603, 703) and the second coiled strip of conductive material (603, 703) form the first pair of coiled strips of conductive material; and at least one additional pair of coiled strips of conductive material, wherein the at least one additional pair of coiled strips of conductive material and the first pair of coiled strips of conductive material form a set of pairs of coiled strips of conductive material; Wherein, (i) each of the conductive material winding strips (603, 703) in the group of conductive material winding strip pairs is wound in a first direction; (ii) each pair of conductive material winding strips in the group of conductive material winding strip pairs has a coil wound inwardly and a coil wound outwardly; and (iii) the group of conductive material winding strip pairs are arranged adjacent to each other in the axial direction of the axial flux motor, so that a pair of coils wound inwardly is never adjacent to another pair of coils wound outwardly.

23. The axial flux electric machine of claim 1 further comprising: a second rotor spaced apart from the stator (101, 400) in the axial direction of the axial flux motor and opposed to the rotor (102, 300); and A rotor (102, 300) shaft is fixedly connected to the rotor (102, 300) and the second rotor.

24. The axial flux electric machine according to claim 1, wherein: The conductive material coiled strip (603, 703) is configured as follows: winding in a first plane from a first external electrical contact terminal (1005) toward a center of the pole piece; bending from the first plane to a second plane; winding in the second plane from the center of the pole piece toward a second external electrical contact terminal (1005); and A conductive path is formed from the first external electrical contact terminal (1005) to the second external electrical contact terminal (1005).

25. The axial flux electric machine of claim 1 further comprising: a second rotor spaced apart from the stator (101, 400) in the axial direction of the axial flux motor and opposed to the rotor (102, 300); and A rotor (102, 300) shaft is fixedly connected to the rotor (102, 300) and the second rotor.

26. The axial flux electric machine of claim 1 further comprising: a second stator, the second stator being spaced apart from the stator (101, 400) in the axial direction of the axial flux motor; and a second rotor spaced apart from the second stator in an axial direction of the axial flux motor; Wherein: (i) the stator (101, 400) is energized to rotate the rotor (102, 300); and (ii) the second stator is energized to rotate the second rotor.

27. The axial flux electric machine of claim 1 further comprising: A first rotor shaft (1801); A second rotor shaft (1802); and A mechanical differential assembly configured to allow the first rotor shaft (1801) and the second rotor shaft (1802) to move in relative rotation while transmitting torque from the rotor (102, 300) to the first rotor shaft (1801) and the second rotor shaft (1802).

28. The axial flux electric machine of claim 27, further comprising: a second rotor, the second rotor being spaced apart from the stator (101, 400) in the axial direction of the axial flux motor and being opposite to the rotor (102, 300); and A second mechanical differential assembly, the second mechanical differential assembly is configured to allow the first rotor shaft (1801) and the second rotor shaft (1802) to move in relative rotation while transmitting torque from the second rotor to the first rotor shaft (1801) and the second rotor shaft (1802).

29. The axial flux electric machine of claim 1, wherein: The axial flux machine is an electric motor.

30. An axial flux motor, comprising: A stator (101, 400), wherein the stator (101, 400) has a plurality of pole pieces; a rotor (102, 300), the rotor (102, 300) being spaced apart from the stator (101, 400) in the axial direction of the axial flux motor; and a coil of conductive material, the coil of conductive material forming at least a portion of a pole piece (1201, 1705) of a plurality of pole pieces; Wherein, the coil of conductive material forms a pole piece as an independent structure.

31. An axial flux motor, comprising: A stator (101, 400), wherein the stator (101, 400) has a plurality of pole pieces; a rotor (102, 300), the rotor (102, 300) being spaced apart from the stator (101, 400) in the axial direction of the axial flux motor; and a coiled strip (603, 703) of conductive material, the coiled strip (603, 703) of conductive material forming at least a portion of a pole piece (1201, 1705) of a plurality of pole pieces; Therein, the radial surface area of ​​the coiled strip forms at least half of the radial surface area of ​​the pole piece.

32. The axial flux electric machine of claim 31 further comprising: A coiled strip (601, 701) of soft magnetic material, the coiled strip (601, 701) of soft magnetic material forming at least a portion of a pole piece; The soft magnetic material coiled strips (601, 701) and the conductive material coiled strips (603, 703) are coiled together to form the interlaced composite material coil (500).

33. An axial flux motor, comprising: stator (101, 400); a rotor (102, 300), the rotor (102, 300) being spaced apart from the stator (101, 400) in the axial direction of the axial flux motor; A second rotor spaced apart from the rotor (102, 300) in an axial direction of the axial flux machine; and The rotor (102, 300) shaft is fixedly connected to the rotor (102, 300) and the second rotor, respectively.

34. An axial flux motor, comprising: stator (101, 400); a rotor (102, 300), the rotor (102, 300) being spaced apart from the stator (101, 400) in the axial direction of the axial flux motor; a second stator, the second stator being spaced apart from the stator (101, 400) in the axial direction of the axial flux motor; and a second rotor spaced apart from the second stator in an axial direction of the axial flux motor; Wherein: (i) the stator (101, 400) is energized to rotate the rotor (102, 300); and (ii) the second stator is energized to rotate the second rotor.

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