System and device for a segmented axial field rotational energy device

Abstract

Axial field rotational energy device comprising: a rotor (33) comprising a rotational axis (35) and a magnet (37); and a stator (141) which is coaxial to the rotor (33), wherein the stator (141) comprises a plurality of stator segments (142) which are coupled to each other around the axis, wherein each stator segment (142) comprises a printed circuit board, PCB, (145) with a plurality of PCB layers (47), wherein the PCB layers (47) form at least two layer pairs (57). wherein the two PCB layers (47) of each layer pair (57) are electrically coupled to each other via vias (155, 159) and wherein each PCB layer (47) comprises a plurality of coils (149) that are coplanar and angularly spaced from each other with respect to the axis of rotation (35), wherein each coil (149) is wound from a section-by-section continuous conductor and is concentric in a single plane from an outermost coil section to a concentric innermost coil section, wherein the coils (149) in adjacent PCB layers (47) are oriented circumferentially relative to the axis to define symmetrical stacks of coils (149) in the axial direction, and each stator segment (142) comprises only one electrical phase, wherein each coil (149) has a first terminal (51) at the outer edge of the coil (149) and a second terminal (53) in the center of the coil (149), wherein a first via (55.1) couples the second terminal (53) of a first coil (49.11) of the plurality of coils (149) of a first PCB layer (47.1) of a layer pair (57.1) with a second terminal (53) of a second coil (49.21) of the plurality of coils (149) of a second PCB layer (47.2) adjacent to the first coil of the layer pair (57.1) and wherein a second via (55.2) couples the first terminal (51) of the second coil (49.21) of the plurality of coils (149) of the second PCB layer (47.2) of the layer pair (57.1) with a first terminal (51) of a further coil (49.12) adjacent to the first coil of the plurality of coils (149) of the first PCB layer (47.1) of the layer pair (57.1).

Description

[0001] This application claims priority to and the benefit of U.S. Provisional Application No. 62 / 445,091, filed January 11, 2017, U.S. Provisional Application No. 62 / 445,211, filed January 11, 2017, U.S. Provisional Application No. 62 / 445,289, filed January 12, 2017, U.S. Provisional Application No. 62 / 457,696, filed February 10, 2017, U.S. Provisional Application No. 62 / 609,900, filed December 22, 2017, and U.S. Application No. 15 / 864,604, filed January 8, 2018, each of which is incorporated herein by reference in its entirety.

[0002] The present invention relates generally to an axial field rotary energy device and, more particularly, to a system, method, and apparatus for modular motors and generators having one or more printed circuit board (PCB) stators.

[0003] Conventionally, axial air-gap brushless motors with stacked disc stators are known, such as US 5,789,841. This patent discloses a stator winding using wires interconnected in a wave or wound configuration. Such motors are relatively large and difficult to manufacture. Axial-field electric devices using PCB stators are also known, such as US 6,411,002, US 7,109,625, and US 8,823,241. However, some of these designs are complex, relatively expensive, and non-modular. Therefore, improvements in low-cost, axial-field rotary energy devices continue to be of interest.

[0004] Patent application US 2014 / 0175922 A1 describes an axial rotary energy device with a segmented stator assembly comprising a plurality of segments, the segments arranged in an annular array. Each stator segment is constructed by stacking a plurality of PCB power conductor layers and a plurality of PCB series layers. Each layer has radial conductors extending from an inner via to an outer via. The vias electrically connect selected radial conductors of the series layers and the power conductor layer. Each power conductor layer includes a pair of positive and negative terminal vias for one phase of the electrical current, which are connected to selected outer vias.A daughter board electrically connects two adjacent segments by having a first portion electrically connected to a negative terminal via in one segment and a second portion electrically connected to a positive terminal via in an adjacent segment, along with a power conductor electrically connecting the two terminal vias.

[0005] European patent application EP 2 863 524 A1 discloses a stator for an axial flux machine. The stator is constructed from a printed circuit board (PCB) and includes a method for cooling such a stator. The printed circuit board of the stator comprises at least one conductive track forming a stator winding and at least one cooling channel formed in at least one electrically insulating substrate layer of the PCB for conveying a mixture of compressed air and a cooling liquid mist. The cooling channel is arranged such that the mixture is in physical contact with the conductive track to cool the conductive track.

[0006] Chinese patent application CN 000105871089 A discloses a printed circuit board stator with two layer modules. The upper layer module and the lower layer module are arranged in a disc structure, on which a plurality of fan-shaped winding elements are applied. Each winding element comprises a fan-shaped printed circuit board with a first, a second, and a third coil on the upper layer module and a fourth, fifth, and sixth coil on the lower layer module.Each coil has an outer and an inner connection; the outer connections of the three coils on the upper layer module and the outer connections of the three coils on the lower layer module are arranged in parallel along the circumferential direction one after the other; the inner connections of the three coils, which correspond to each other, are connected on the top and bottom sides through corresponding through holes; the electrical angle between the upper layer module and the lower layer module is 360 degrees; and the outer connections of the coils in the upper layer module are respectively connected to the outer connections of the coils at corresponding positions in the lower layer module. The upper layer module and the lower layer module each form the winding elements through independent circuit boards, so that the entire circuit board stator is suitable for a high-performance motor or generator.

[0007] Chinese Patent Application CN 105896760 A discloses a disc-shaped coreless permanent magnet motor using a modular printed circuit board stator. The disc-shaped coreless permanent magnet motor comprises a rotor and a stator, the stator being formed by superimposing printed circuit boards along the axial direction; each printed circuit board is divided into at least two modules; the same winding coils are evenly printed on each module along the circumferential direction; the winding coils of two adjacent modules are connected in series or parallel in the circumferential direction; and the winding coils of two adjacent printed circuit boards are connected in series or parallel in the axial direction.The disc-shaped coreless permanent magnet motor reduces production costs, improves the power density of the motor, and is suitable for use as a disc-shaped permanent magnet motor with all structure types.

[0008] Patent application US 2015 / 0318751 A1 discloses a system having a machine segment comprising a plurality of coils. Each coil is electrically isolated from the other coils in the machine segment, and each coil is electrically connected to at least one electrical terminal to provide electrical access to the coil. Each electrical terminal provides electrical access to the coil to which it is electrically connected, allowing the coil to be removably electrically connected to an electrical circuit. The machine segment is further configured to be removably mechanically coupled to a second machine segment to form at least part of a stator or part of a rotor.

[0009] Further prior art includes US application documents US 2013 / 0 049 500 A1 and US 2010 / 0 253 170 A1; as well as US 2006 / 0 202 584 A1, US 2005 / 0 285 470 A1, and US 2009 / 0 051 317 A1; and US patent documents US 7 573 173 B1 and US 8 736 133 B1. Chinese patent application CN 1 06 300 856 A is also prior art and is listed here. Furthermore, German documents DE 10 2015 211 852 A1 and DE 296 22 874 U1 are also listed. Reference is also made to WO 2009 / 068079 A1 and European application EP 2 284 979 A1.

[0010] Embodiments of a system, method, and apparatus for an axial-field rotary energy device are disclosed. An axial-field rotary energy device may include, for example, a rotor comprising a rotational axis and a magnet; and a stator coaxial with the rotor, the stator comprising a plurality of stator segments coupled together about the axis, each stator segment comprising a printed circuit board (PCB) having a PCB layer including a coil, and each stator segment comprising only one electrical phase.

[0011] Another embodiment of an axial-field rotary energy device may include a rotor having a rotational axis and a magnet; and a stator coaxial with the rotor, the stator comprising a plurality of stator segments coupled together about the axis, each stator segment comprising a printed circuit board (PCB) having a plurality of PCB layers, each comprising a coil, the PCB layers being spaced apart from each other in an axial direction, each of the PCBs having an even number of PCB layers, the PCB layers comprising layer pairs, each layer pair being defined as two PCB layers electrically coupled together with a via, and each layer pair being coupled to another layer pair via another via.

[0012] Yet another axial-field rotary energy device may include a rotor having a rotational axis and a magnet; and a stator coaxial with the rotor, wherein the stator includes a plurality of stator segments and a plurality of electrical phases, each stator segment includes a printed circuit board (PCB) having at least one PCB layer with a coil, and each stator segment includes only one electrical phase.

[0013] The foregoing and other objects and advantages of these embodiments will become apparent to those skilled in the art upon consideration of the following detailed description when considered in conjunction with the appended claims and the accompanying drawings.

[0014] In order that the manner in which the features and advantages of the embodiments are achieved and may be more fully understood, a more particular description may be obtained by reference to the embodiments thereof illustrated in the accompanying drawings. However, the drawings illustrate only some embodiments and are therefore not to be considered limiting of the scope, as other equally effective embodiments may exist. Fig. 1 is a plan view of one embodiment of an axial field rotational energy device. Fig. Figure 2 is a side sectional view of the device of Fig. 1 along line 2-2 from Fig. 1. Fig. 3 is an exploded isometric view of an embodiment of the device of the Fig. 1 and Fig. 2. Fig. 4 is a plan view of one embodiment of a single-phase stator having a printed circuit board (PCB). Fig. 5 is an enlarged isometric view of an embodiment of only the coil layers of a stator. Fig. 6A is an enlarged, exploded isometric view of another embodiment of only the coil layers of a stator. Fig. 6B is an enlarged isometric view of a portion of the Fig. 5 shown stator. 5. Fig. 6C is an enlarged isometric exploded view of a portion of the Fig. 5 shown stator. Fig. Figure 6D is an enlarged isometric view of a portion of the Fig. 5 shown stator. Fig. Figure 7 is a schematic, partially exploded side view of one embodiment of the conductive traces on the layers of a stator. Fig. 8 is a plan view of one embodiment of a multi-phase stator having a PCB. Fig. Figure 9 is a plan view of an alternative embodiment of the upper coil layer of a stator and the magnets of the vertically adjacent rotors. Fig. 10 is a simplified plan view of an embodiment of another embodiment of an axial field rotary energy device. Fig. Figure 11 is a simplified side sectional view of the device of Fig. 10. Fig. 12 is a simplified isometric exploded view of an embodiment of the device of the Fig. 10 and Fig. 11. Fig. 13 is a simplified plan view of one embodiment of a segmented stator. Fig. 14 is a simplified plan view of another embodiment of a segmented stator. Fig. 15 is a simplified plan view of one embodiment of conductive traces for a PCB. Fig. 16 is a simplified isometric view of the embodiment of Fig. 15. Fig. 17 is a schematic, isometric exploded view of one embodiment of circuit trace layers of the PCB of the Fig. 15 and Fig. 16. Fig. 18 is a plan view of one embodiment of a module. Fig. 19 is a side sectional view of the module from Fig. 18 along line 19-19 from Fig. 18. Fig. 20A is an exploded isometric view of an embodiment of the module of the Fig. 18 and Fig. 19. The Fig. 20B-20H are isometric and side sectional views of embodiments of the module of Fig. 20A. Fig. 21 is an exploded isometric view of another embodiment of a module. Fig. 22 is a composite isometric view of an embodiment of the module of Fig. 21. The Fig. 23 and Fig. 24 are isometric views of one embodiment of stacked modules with open and closed locks, respectively. Fig. 25 is an interior top view of one embodiment of a module. Fig. 26 is an exploded isometric view of one embodiment of a body for modules. Fig. 27 is a plan view of one embodiment of a PCB stator for an axial field rotary energy device. Fig. 28 is an enlarged plan view of a portion of one embodiment of the PCB stator of Fig. 27. Fig. 29 is an isometric view of one embodiment of a stator including attached sensors. Fig. 30 is an isometric view of one embodiment of a stator incorporating embedded sensors. Fig. 31 is an isometric view of one embodiment of a stator segment assembly. Fig. 32 is an isometric view from the opposite side of one embodiment of a stator segment assembly.

[0015] Fig. 1-4, 8 and 13 show embodiments not according to the invention.

[0016] The use of the same reference symbols in different drawings indicates similar or identical elements.

[0017] The Fig. 1-3 illustrate various views of an embodiment of a device 31 including an axial field rotational energy device (AFRED). Depending on the patent application, the device 31 may include a motor that converts electrical energy into mechanical power or a generator that converts mechanical power into electrical energy. I. PLATES

[0018] Embodiments of the device 31 may include at least one rotor 33 comprising a rotation axis 35 and a magnet (ie, at least one magnet 37). A plurality of magnets 37 are provided in the embodiment of Fig. 3. Each magnet 37 may include at least one magnetic pole.

[0019] The device 31 may also include a stator 41 that is coaxial with the rotor 33. The rotor 33 may be coupled to a shaft 43 and other hardware, such as one or more of the following: a mounting plate, fastener, disc, bearing, spacer, or alignment element. Embodiments of the stator 41 may include a single, one-piece plate, such as the one shown in Fig. 4. The PCB 45 may include at least one PCB layer 47. Certain embodiments described herein include twelve PCB layers 47. The PCB layers 47 may be parallel and spaced apart in the axial direction. Each PCB layer 47 may include at least one conductive trace 49. Each conductive trace 49 is a separate conductive feature formed on a given PCB layer 47. In Fig. 4. For example, eight conductive paths 49 are shown. The conductive paths 49 can be configured in a desired pattern, such as the one shown in Fig. 4 illustrated coils.

[0020] Fig. 4 illustrates one embodiment of a PCB layer 47 within a twelve-layer PCB 45. The other eleven PCB layers are similar, with the differences described below with reference to the subsequent figures. On the illustrated PCB layer 47, each trace 49 (forming a single coil) includes a first terminal 51 at the outer edge of the coil and a second terminal 53 in the center of the coil. The traces 49 are connected to other traces 49 using vias 55. A first group of vias 55 is disposed adjacent to the first terminal 51 at the outer edge of each coil, and a second group of vias 55 is disposed adjacent to the second terminal in the center of each coil.In this embodiment, the conductive traces 49 on the illustrated PCB layer 47 are not directly connected to an adjacent conductive trace 49 on that illustrated PCB layer 47, but instead are each directly connected to a corresponding conductive trace 49 on another PCB layer 47, as described in more detail with reference to FIG. Fig. 5 and the Fig. 6A-6D explained.

[0021] In this embodiment, each conductive trace 49 is continuous and uninterrupted from its first terminal 51 to its second terminal 53, and connections to such a conductive trace 49 are made only to the first and second terminals 51, 53. Each conductive trace 49 includes no further terminals for electrical connections. In other words, each conductive trace 49 between the first and second terminals 51, 53 may be seamlessly continuous with no other electrical connections, including no other vias 55. As also shown in Fig. 4, the width of a given trace 49 may not be uniform. For example, the width 171 corresponding to an external trace corner may be greater than the width 173 corresponding to an internal trace corner. The gap 175 between adjacent concentric trace sections forming a single coil may be the same as or different from the gap 177 between adjacent traces (i.e., separate coils). In some embodiments, a given trace may include an outer width adjacent to an outer diameter of the PCB and in a plane perpendicular to the axis 35, and an inner width adjacent to an inner diameter of the PCB and in the plane. In some embodiments, the outer width may be greater than the inner width. In some embodiments, a given trace may include opposing inner and outer edges that are not parallel to each other.

[0022] Fig. 5 illustrates an embodiment of a twelve-layer PCB 45 incorporating the Fig. 4. Each of the twelve PCB layers 47 are closely spaced and form a "sandwich" of the PCB layers 47, labeled 47.1-12. On the topmost PCB layer 47.1, a first conductive trace 49.11 (also described herein as "coil 49.11") is shown, the first terminal 51.1 of which is coupled to an external terminal 61 for the device 31. On the bottommost PCB layer 47.12, a conductive trace 49.128 is shown, the first terminal 51.12 of which is coupled to an external terminal 63 for the device 31. In this embodiment, eight conductive traces 49 (coils) are present on each of twelve PCB layers 47.1-12.These traces are coupled together (as described in more detail below), so that current flowing into external terminal 61 flows through the ninety-six coils, then out of external terminal 63 (or conversely, flows into external terminal 63 and out of external terminal 61). In this embodiment, only one trace 49 (e.g., coil 49.11) is coupled to external terminal 61 for device 31, and only one trace 49 (e.g., coil 49.128) is coupled to external terminal 63 for device 31. For a motor, both external terminals 61, 63 are input terminals, and for a generator, both external terminals 61, 63 are output terminals.As can be seen in this embodiment, each PCB layer includes a plurality of coils that are coplanar and angularly and symmetrically spaced from each other about the axis, and the coils in adjacent PCB layers, relative to the axis, are circumferentially aligned with each other relative to the axis to define symmetrical stacks of coils in the axial direction.

[0023] Fig. 6A is an exploded view of a portion of the Fig. 5, which is labeled to better illustrate how the coils are coupled together via vias 55, 59, and thus to better illustrate how current flows into external terminal 61, through the ninety-six coils, then out of external terminal 63. Input current 81.1 is assumed to flow into external terminal 61. This current flows as currents 81.2 and 81.3 "spiraling" around coil 49.11 (on PCB layer 47.1) and reaches the second terminal 53 of coil 49.11. A via 55.1 couples the second terminal 53 of coil 49.11 to the second terminal of the corresponding coil 49.21 on PCB layer 47.2 directly below coil 49.11. Thus, the current flows through the via 55.1 as current 81.4, then flows spirally as current 81.5 around the coil 49.21 until it reaches the first terminal 51 for the coil 49.21.A via 55.2 couples the first terminal 51 of coil 49.21 to the first terminal of coil 49.12 on PCB layer 47.1, which is adjacent to the first coil 49.11. In this embodiment, the conductive traces 49 on the first PCB layer 47.1 are generally reversed (mirror-imaged) relative to those on the second PCB layer 47.2, such that the via 55.1 overlaps with both "tabs" on the respective second terminal 53 of coils 49.11 and 49.21, and also such that the via 55.2 overlaps with both "tabs" on the respective first terminal 51 of coils 49.12 and 49.21, as described in more detail below with reference to the subsequent figures. Thus, the current flows as current 82.1 through the via 55.2 to the first terminal 51 of the coil 49.12 on the PCB layer 47.1.

[0024] From this terminal, the current flows through coils 49.12 and 49.22 in a similar manner to that described for coils 49.11 and 49.21. For example, the current flows around coil 49.21 (on PCB layer 47.1) as currents 82.2 and 82.3 to the second terminal 53 of coil 49.21, flows through via 55.3 as current 82.4 to the second terminal 53 of coil 49.22, then flows around coil 49.22 as currents 82.5 and 82.6 until it reaches the first terminal 51 for coil 49.22. As before, a via 55.4 couples the first terminal 51 of coil 49.22 to the first terminal 51 of coil 49.13 on PCB layer 47.1, which is adjacent to coil 49.12. This coupling configuration is repeated for all remaining traces 49 on the top two PCB layers 47.1, 47.2, and the current flows through these remaining traces 49 until it reaches the last coil 49.28 on PCB layer 47.2.The current, having already flowed through all sixteen coils on the top two PCB layers 47.1, 47.2, is now conducted to the next PCB layer 47.3. A via 59.1 specifically couples the first terminal 51 of coil 49.28 to the first terminal of coil 49.31 on PCB layer 47.3, which is located directly below coils 49.11 and 49.21. In this embodiment, only one such via 59 is present, coupling a coil on PCB layer 47.2 to a coil on PCB layer 47.3. Conversely, fifteen such vias 55 are present, which together couple coils on PCB layers 47.1, 47.2. In this embodiment, such coupling occurs only at the first and second terminals 51, 53 of the coils.

[0025] The vias 55 between the third and fourth PCB layers 47.3, 47.4 are configured identically to those between the first and second PCB layers 47.1, 47.2 described above, and therefore the via configuration and corresponding current flow do not need to be repeated. It continues downward through the PCB "sandwich" layer until the bottommost PCB layer 47.12 is reached (not shown here). As described above, the first terminal 51 for the conductive track (coil) 49.128 is coupled to the external terminal 63. Consequently, the current flowing inward through the external terminal 61, after flowing through all ninety-six coils, flows outward through the external terminal 63.

[0026] Fig. Figure 6B is an enlarged view of a group of vias 55 formed in Fig. 5. This via group is adjacent to the respective second terminal 53 for each of a group of vertically aligned coils 49.1-12 on each of the twelve PCB layers 47.1-12. As stated above, the conductive traces 49 on the second PCB layer 47.2 are generally reversed (mirror-imaged) relative to those on the first PCB layer 47.1, such that the via 55 overlaps with both "tabs" on the respective second terminal 53 of these vertically adjacent coils. As shown in Fig. As shown in Figure 6B, the second terminal 53.18 on coil 49.18 (first layer, eighth coil) includes a tab extending toward the side of the trace. Mirrored, the second terminal 53.28 on coil 49.28 (second layer, eighth coil) includes a tab extending in the opposite direction toward the side of the trace, so that these two tabs overlap. A via 55 couples these two overlapping tabs together. Since the illustrated embodiment includes 12 PCB layers 47, each of the five additional vias 55 similarly couples the overlapping terminals 53.38 and 53.48, the overlapping terminals 53.58 and 53.68, the overlapping terminals 53.78 and 53.88, the overlapping terminals 53.98 and 53.108, and the overlapping terminals 53.118 and 53.128, respectively.

[0027] Fig. Figure 6C shows two of these vias 55 in an exploded format. Terminal 53.38 of coil 49.38 overlaps terminal 53.48 of coil 49.48, and they are coupled together via a first via 55. Terminal 53.58 of coil 49.58 overlaps terminal 53.68 of coil 49.68, and they are coupled together via a second via 55. As can be clearly seen from the figures, these pairs of overlapping tabs, along with their corresponding vias 55, are radially offset, so that such vias 55 may be implemented using plated through-hole vias. Alternatively, such vias 55 may be implemented as buried vias, in which case the vias need not be offset, but rather may be vertically aligned.

[0028] Fig. Figure 6D is an enlarged view of a group of vias 59 also shown in Fig. 5. In this embodiment, these vias 59 are arranged in the gap between a specific adjacent pair of vertically aligned coils 49 (e.g., between the top layer coils 49.11 and 49.18), while the vias 55 are arranged in the other gaps between other adjacent pairs of vertically aligned coils 49. In this figure, the vias 59 are shown as placed through-hole vias. The vias 55, 59 overlap with both "tabs" on the corresponding first terminal 51 of the respective coils. The vias 55 couple horizontally adjacent coils on vertically adjacent layers, while the vias 59 couple horizontally aligned coils on vertically adjacent layers, both as in Fig. 6A. In this embodiment, only five vias 59 are shown because the first terminal 51 on the topmost coil 49.11 is coupled to the external terminal 61, and the first terminal 51 of coil 49.128 on the bottommost PCB layer 47.12 is coupled to the external terminal 63, leaving only 10 PCB layers (47.2-11) that have coils whose respective first terminals 51 are coupled to each other in pairs. For example, the innermost via 59.5 couples a respective coil on PCB layer 47.10 to a respective coil on PCB layer 47.11.

[0029] In various embodiments, each conductive trace 49 may be electrically coupled to another conductive trace 49 with at least one via 55. In the example of Fig. 6A, each PCB layer 47 has nine traces 49 and only one via 55 between the traces 49. In some embodiments, each trace 49 is electrically coupled to another trace 49. Two traces 49 together define a trace pair 57. In Fig. 7 there are twelve PCB layers 47.1-12 and six conductor track pairs 57.1-6.

[0030] Each trace pair 57 may be electrically coupled to another trace pair 57 with at least one via 59 (e.g., such as only one via 59). In some versions, the traces 49 (e.g., coils) in each trace pair 57 (e.g., coil pair) may be located on different PCB layers 47, as shown in Fig. 6A. However, in other versions, the traces 49 in each trace pair 57 may be coplanar and located on the same PCB layer 47.

[0031] In some embodiments, at least two of the conductive traces 49 (e.g., coils) are electrically coupled in series. In other versions, at least two of the conductive traces 49 (e.g., coils) are electrically coupled in parallel. In still other versions, at least two of the conductive traces 49 are electrically coupled in parallel, and at least two other conductive traces 49 are electrically coupled in series.

[0032] Embodiments of the device 31 may include at least two of the conductive trace pairs 57 electrically coupled in parallel. In other versions, at least two of the conductive trace pairs 57 are electrically coupled in series. In still other versions, at least two of the conductive trace pairs 57 are electrically coupled in parallel, and at least two other conductive trace pairs 57 are electrically coupled in series.

[0033] As in the Fig. 4 and Fig. 6, each PCB layer 47 (only the topmost PCB layer 47 is shown in the top views) includes a PCB layer surface area (LSA), which is the total surface area (TSA) of the entire (top) surface of the PCB 45. The TSA does not include the holes in the PCB 45, such as the center hole and the mounting holes, which are illustrated. The one or more conductive traces 49 (eight in Fig. 4) on the PCB layer 47 may include a coil surface area (CSA). The CSA includes the entire footprints of the coils (i.e., within their perimeters), not just their "copper surface area." The CSA may be in a range of at least about 50% of the surface area of ​​the PCB layer, such as at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, at least about 95%, at least about 97%, or even at least about 99% of the surface area of ​​the PCB layer.In other embodiments, the coil surface area may be no greater than 99% of the surface area of ​​the PCB layer, such as no greater than about 95%, no greater than about 90%, no greater than about 85%, no greater than about 80%, no greater than about 75%, or even no greater than about 70% of the surface area of ​​the PCB layer. In other embodiments, the coil surface area may range between any of these values.

[0034] The CSA can also be calculated with reference to any sensors or circuits (such as IoT elements) on or in the PCB. The IoT elements can be limited to no more than 50% of the TSA. Furthermore, the IoT elements can be embedded within the CSA or embedded in at least a portion of the TSA that is not included in the CSA.

[0035] The entire area of ​​each conductive trace forming a coil (i.e., including the conductive traces, but not necessarily including the spaces between the conductive traces) can be considered the coil surface area. It is believed that the performance of device 31 improves with increasing aggregate coil surface area relative to the underlying surface area of ​​the PCB layer on which the coil(s) are formed.

[0036] In some embodiments ( Fig. 4) The device 31 may include a stator 41 comprising a single electrical phase. Versions of the stator 41 may consist of a single electrical phase. Each PCB layer 47 may include a plurality of coils spaced coplanarly and symmetrically about the axis 35 ( Fig. 2 and Fig. 3). In one example, each coil consists of a single electrical phase,

[0037] Fig. Figure 8 illustrates an embodiment of the stator 41 that includes at least two electrical phases (e.g., the three phases shown). Each PCB layer 47 may include a plurality of coils (such as conductive traces 49), as shown for each electrical phase. Fig. For example, Figure 8 illustrates coils corresponding to the three phases A, B, and C. The coils for each electrical phase A, B, C may be angularly offset from each other within each PCB layer 47 with respect to the axis 35 ( Fig. 2 and Fig. 3) to define a desired phase shift between the electrical phases A, B, C. In Fig. 6A, nine conductor tracks 49 are present on each PCB layer 47. Since the embodiment of the stator 41 in Fig. 8 is three phases, each conductor track 49 in phase A is spaced 120 electrical degrees from the other conductor tracks 49 for phase A and 40 electrical degrees from the adjacent conductor tracks 49 for phases B and C. The conductor tracks 49 for phase B (relative to phases A and C) and for phase C (relative to phases A and B) are equally spaced.

[0038] In some embodiments, each coil (e.g., trace 49) may consist of a single electrical phase. Alternatively, the coils may be configured to supply the stator 41 with two or more electrical phases (e.g., the three in Fig. 8 phases shown).

[0039] The example from Fig. 9 is a simplified view of only some of the internal components of one embodiment of the device 31. Each of the magnets 37 may include a radial magnetic edge or a radial magnetic element 67 (also referred to herein as "radial magnetic edge 67"), and each of the conductive traces 49 may include a radial conductive trace edge or a radial conductive trace element 69 (also referred to herein as "radial coil edge 69"). The magnets 37 are part of the rotor 33 ( Fig. 2) and rotate about the axis 35 with respect to the stationary stator 41. When radial edge portions of the magnets 37 and the conductive traces 49 rotationally align relative to the axis during operation of the device 31, at least portions of the radial elements 67, 69 may be skewed (i.e., not parallel) relative to each other. In some embodiments, when radial edge portions of the magnets and the coils rotationally align relative to the axis, the radial magnet edges and the radial coil edges are not parallel and are angularly skewed relative to each other. Fig. 9 illustrates a rotational position of the magnets 37 for which a radial edge portion of the magnet 37 (i.e., the radial magnet edge 69 approaches the corner of the magnet 37) rotationally aligns with a radial edge portion of the coil 49 and which illustrates the skew between the radial magnet edge 69 and the radial coil edge 67. In one version, the radial elements 67, 69 may be leading radial edges or trailing radial edges of the magnets 37 and the conductive traces 49. In another example, the radial magnet and conductive trace edges or elements 67, 69 may be linear as shown, and the portions of the radial magnet and conductive trace elements 67, 69 are not parallel when the magnets 37 and the conductive traces 49 rotationally align in the axial direction.

[0040] In some embodiments, the radial magnetic elements 67 may be angularly skewed relative to the radial conductive trace elements 69, and the angular skewing may be greater than 0 degrees, for example, greater than 0.1 degrees, at least about 1 degree, at least about 2 degrees, at least about 3 degrees, at least about 4 degrees, or even at least about 5 degrees. In other versions, the angular skewing may be no greater than about 90 degrees, such as no greater than about 60 degrees, no greater than about 45 degrees, no greater than about 30 degrees, no greater than about 25 degrees, no greater than about 15 degrees, no greater than about 10 degrees, or even no greater than about 5 degrees. Alternatively, the angular skewing may range between any of these values.

[0041] In an alternative embodiment, at least portions of the radial elements 67, 69 may be parallel to each other during rotational alignment. II. SEGMENTS

[0042] Some embodiments of an axial-field rotary energy device may be configured in a manner similar to that described for device 31, including the mounting hardware, except that the stator may be configured slightly differently. Fig. For example, Figures 10-12 illustrate a simplified version of a device 131 with only a few elements for easier understanding. The device 131 may include a stator 141 that is coaxial with a rotor 133. Optionally, each rotor 133 may have one or more slots or grooves 136 ( Fig. 10) extending therethrough. In some versions, the grooves 136 are angled with respect to the axis 135 ( Fig. 12) and therefore do not run solely vertically. The angles of the grooves 136 may be provided at constant inclinations and may allow for cooling airflow within the device 131. The grooves 136 may allow for airflow that is pulled or pushed through and / or around the rotors 133 and effectively cools the stators 141. Additional grooves may be provided in rotor spacers, such as a rotor spacer 143 ( Fig. 12), in particular in embodiments having a plurality of stator segments, and in particular in embodiments having an inner diameter R-INT of the stator arrangement ( Fig. 14) regardless of the outer diameter R-EXT.

[0043] Instead of a single-plate PCB 45, as described for the stator 41, the stator 141 may include a plurality of stator segments 142, each of which may be a separate PCB 145. The stator segments 142 may be coupled together, for example, mechanically and electrically coupled. Each stator segment 142 may include a printed circuit board (PCB) having one or more PCB layers 147 ( Fig. 13), as described elsewhere herein. In one example, each PCB 145 may have an even number of PCB layers 147. In an alternative embodiment, each PCB 145 may have an odd number of PCB layers 147.

[0044] Embodiments of the stator segments 142 may include or correspond to only one electrical phase. Furthermore, the stator 141 of the device 131 may consist of or correspond to only one electrical phase. In other versions, the stator 141 may include or correspond to a plurality of electrical phases. As shown in Fig. 13, each stator segment 142 includes at least one PCB layer 147 having at least one conductive trace 149, such as the illustrated coil. In some versions ( Fig. 14), each stator segment 142 may include at least one PCB layer 147 having a plurality of conductive traces 149 (e.g., coils) that are coplanar and angularly spaced from each other relative to the axis 135 ( Fig. 11 and Fig. 12). In one example, each conductive trace 149 may comprise a single electrical phase. In another version, each stator segment 142 may include a plurality of PCB layers 147, each of which may be configured to correspond to only one electrical phase. In some versions, each PCB layer 147 on each stator segment 142 may include a plurality of axially coplanar conductive traces 149 configured to correspond to only one electrical phase.

[0045] In some embodiments ( Fig. 13), each PCB layer 147 may include at least one radial trace 150 extending from approximately an inner diameter (ID) of the PCB 145 to approximately an outer diameter (OD) of the PCB 145. In one example, each PCB layer 147 may include a trace 149 that is continuous from an outermost trace portion 152 to an innermost concentric trace portion 154. The traces 149 may include radial traces 150 having linear sides and chamfered corners 156. The linear sides of the radial traces may be tapered, having an increasing trace width with increasing radial pitch. Traces on the inner end turn 146 and traces on the outer end turn 148 extend between the radial traces 150 to form a concentric coil.

[0046] Regarding tapered conductors and coils, the tapers can increase the amount of conductive material (e.g., copper) that can be included in a PCB stator. Since many motors and generators are round in shape, the coils can generally be circular, and in order to fit together on a stator, the circumferences of the coils can be slightly pie-shaped or triangular. In some versions, the coils can have an equal width in a plane perpendicular to the axis, and in other versions, the coils can be tapered to increase the conductor (e.g., copper) density of the coils. Improving the copper density can be of considerable value in improving electrical resistance. 2 To reduce R losses and heat generation and increase the ability to transfer higher electrical current to provide a higher efficiency machine.

[0047] In another version, each PCB layer 147 can contain only linear tracks 149 ( Fig. 15-17). Linear traces 149 may be continuous from an outermost trace 152 to a concentric innermost trace 154. In one example, no trace 149 of the PCB layers 147 is nonlinear. However, embodiments of the only linear traces 149 may include turns, such as rounded corners or chamfered corners. As used herein, a "turn" includes a trace portion connecting a radial trace to a winding end trace. In other embodiments, the PCB layer 147 may include one or more nonlinear traces, such as curved traces.

[0048] As indicated herein, the PCB 145 may include a plurality of PCB layers 147 spaced apart from each other in the axial direction. The PCB layers 147 may include layer pairs 157 ( Fig. 17; see pairs 157.1 to 157.4). Each layer pair 157 can be defined as two PCB layers that are electrically coupled to each other. In one version, at least one of the PCB layers 147 is electrically coupled to another PCB layer 147 in series or parallel. In another version, at least one layer pair 157 is electrically coupled to another layer pair 157 in series or parallel. In one embodiment, at least one of the layer pairs 157 comprises two PCB layers 147.6 and 147.7 that are axially adjacent to each other. In another embodiment, at least one of the layer pairs 157 comprises two PCB layers 147.1 and 147.3 that are not axially adjacent to each other. Likewise, at least one of the layer pairs 157 can be axially adjacent to the layer pair 157 to which at least one of the layer pairs is electrically coupled.Conversely, at least one of the layer pairs 157 may not be axially adjacent to the layer pair 157 to which at least one of the layer pairs 157 is electrically coupled.

[0049] Embodiments of the PCB layers 147 may include at least one layer group 181 ( Fig. 17). The layer group 181 may include, for example, a first layer 147.1, a second layer 147.2, a third layer 147.3, and a fourth layer 147.4. In some versions, a first via 159 may couple the first layer 147.1 to the third layer 147.3, a second via 155 may couple the third layer 147.3 to the second layer 147.2, and a third via 159 may couple the second layer 147.2 to the fourth layer 147.4. In one example, the first, second, and third vias 159, 155, 159 are the only vias that couple the layer group 181 together. In these examples, the two directly axially adjacent PCB layers 147.1 and 147.2 are not directly electrically coupled to each other. In Fig. 17, each of the vias 159 couples a pair of non-adjacent PCB layers 147 while bypassing the intermediate PCB layer 147 (i.e., no contact is made). For example, via 159.1 couples PCB layer 147.1 to PCB layer 147.3 and does not make contact with PCB layer 147.2. Conversely, each of the vias 155 couples a pair of adjacent PCB layers 147. For example, via 155.2 couples PCB layer 147.2 to PCB layer 147.3. Each via 155, 159, which together couples a respective pair of PCB layers, forms a corresponding layer pair 157. For example, layer pair 157.1 includes PCB layer 147.1 and PCB layer 147.3. Layer pair 157.2 includes PCB layer 147.2 and PCB layer 147.3. Layer pair 157.3 includes PCB layer 147.2 and PCB layer 147.4. Layer pair 157.4 includes PCB layer 147.4 and PCB layer 147.5. Layer pair 157.5 includes PCB layer 147.5 and PCB layer 147.7. Layer pair 157.6 includes PCB layer 147.6 and PCB layer 147.7. Layer pair 157.7 includes PCB layer 147.6 and PCB layer 147.8.

[0050] In Fig. 17, each via is illustrated with a blunt end and a pointed end. This shape is not intended to imply any structural differences between the two ends of each via, but is instead intended to provide a coherent indication of the direction of current flow through each via. Since each via is also illustrated as extending vertically only as far as necessary to couple the corresponding pair of PCB layers 147, in certain embodiments, each via may also be implemented as a plated through-hole via extending through the entire PCB (see, e.g., vias 59 in Fig. 6D). Each of these plated through-hole vias can make contact with any PCB layer 147 having a conductive trace 149 overlapping such a via. Fig. In the embodiment shown in Figure 17, a given through-hole via overlaps and connects to only two PCB layers 147, while the traces 149 of all remaining PCB layers 147 do not overlap the given through-hole via and are not connected to the given through-hole via. Alternatively, some embodiments may include buried through-hole vias that extend vertically only between the respective PCB layers 147 to be connected. III. MODULES

[0051] The Fig. 18, 19, 20A-20H disclose embodiments of a module 201 for one or more axial-field rotary energy devices 231. The device(s) 231 may comprise any of the embodiments of axial-field rotary energy devices disclosed herein. In the embodiments shown in these figures, the module 201 includes a housing 203 having a sidewall 211, three stators (shown as PCB stator plate 245), and four rotor assemblies 242, 244. Each rotor assembly 244 is disposed vertically between two stators 245 and includes a pair of identical rotor plates 236 and a group of rotor permanent magnets 237. Each rotor plate 236 includes a group of recessed notches to position each of the rotor magnets 237, and the two rotor plates 236 are secured together to sandwich each of the groups of rotor magnets between the opposing upper and lower rotor plates 236.Each rotor assembly 242 is disposed vertically between a stator 245 and a housing 203 and includes a torque plate 233, a rotor plate 234, and a group of rotor permanent magnets 237.

[0052] The vertical spacing between two rotor assemblies (e.g., 242, 244) is maintained by spacers (e.g., 262, 263) that extend from one rotor assembly to the adjacent rotor assembly through a hole in the stator intermediate plate 245. The rotor spacing corresponds to the thickness of the stator plate 245 and the desired air gap distance (e.g., above and / or below) the stator plate 245. Each rotor spacer can define the air gap between the rotor assembly and the stator (and can also define the height 215 of the sidewall slots, as mentioned above). Each rotor spacer is positioned between two rotor assemblies. For example, the rotor spacer 262 is positioned between the topmost rotor assembly 242 and the adjacent inner rotor assembly 244 (and likewise for the bottommost rotor assembly 242). Each rotor spacer 263 is positioned between adjacent inner rotor assemblies 244.As illustrated here, such a rotor spacer 263 may have a different thickness than the rotor spacer 262 due to mechanical differences in the upper and lower rotor assemblies 242 relative to the inner rotor assemblies 244 to define the same air gap distance between all rotors and stators. The use of the rotor spacers 262, 263 enables the stacking of multiple rotors (e.g., rotor assemblies 242, 244), providing significant flexibility in the configuration of the module 201.

[0053] Embodiments of the housing 203 may include a side wall 211 ( Fig. 20A-20H and 21). The sidewall 211 may be configured to orient the stator (e.g., stator plate 245) in a desired angular orientation with respect to the axis 235. In applications including a plurality of stators 245, the sidewall 211 may include a plurality of sidewall segments 212. The sidewall segments 212 may be configured to orient the plurality of stators 245 at desired electrical phase angles (see, e.g., Fig. 20C and Fig. 25) for the module 201 to be angularly offset relative to the axis. In one example, the sidewall 211 may include a radially inner surface having one or more slots 214 formed therein. Each slot 214 may be configured to receive and retain the outer edge of the stator 245 to maintain the desired angular orientation of the stator 245 with respect to the axis 235. In the Fig. In the embodiment shown in Figures 20A-20H, each sidewall 211 includes three slots 214 formed between mating pairs of sidewall segments 212. In some embodiments, the upper and lower sidewall segments 212 of such a mating pair are identical and may therefore be used interchangeably, but in other contemplated embodiments, the upper and lower sidewall segments 212 may be different due to differences in mounting hole positioning, asymmetric slots 214, or other aspects.

[0054] In addition to providing the angular offset of the stators 245, as described above, the slots 214 may be configured to axially position the outer edge of each stator 245 at prescribed axial positions with respect to other stators 41, such as vertically. Since the rotor spacers 262, 263 determine the axial distance between each stator 245 (in its innermost extent) and the corresponding rotor assembly (e.g., 242, 244 in the Fig. 20A, Fig. 20B and Fig. 20D) on each axial side (e.g., above and below) of each stator 245, the combination of the sidewall slots 214 (i.e., the height 215 of such slots 214) and the rotor spacers 262, 263 serves to maintain a precise air gap spacing between the stators 245 and the rotor assemblies 242, 244. In other embodiments having a single stator 245, each sidewall segment 212 may be configured to provide one sidewall slot 214. The group of sidewall segments 212 collectively provides numerous slots 214 (e.g., eight such slots 214) spaced radially around the module 201. Such sidewall slots 214 may collectively be considered to facilitate the air gap spacing between the stator and the adjacent rotor.

[0055] Versions of the module 201 may include a housing 203 having mechanical features (e.g., splined shafts 209 in Fig. 21) configured to mechanically couple the housing 203 to a second housing 203 of a second module 201. In addition, the housing 203 may be provided with electrical elements (e.g., the electrical connector couplings 204 in the Fig. 21 and Fig. 22) may be configured to electrically couple the housing 203 to the second housing 203. In one example, the module 201 is air-cooled and is not liquid-cooled. In other versions, liquid-cooled embodiments may be used.

[0056] In some examples, the module 201 may be configured to communicate with the second module 201 with an intermediate structure, such as a frame 205 ( Fig. 21-22). The module 201 may be configured to be directly coupled to the frame 205, such that the module 201 is configured to be indirectly coupled to the second module 201 with other components, depending on the application. In another example, the module 201 may be configured to be directly coupled to the second module 201 without a frame, rack, or other intermediate structure.

[0057] In some embodiments, at least one rotor 233, at least one magnet 237, and at least one stator 241 having at least one PCB 245 with at least one PCB layer 147 having at least one conductive trace 149 may be disposed within and surrounded by the housing 203.

[0058] In some versions, each module 201 consists of a single electrical phase. In other versions, each module 201 comprises a plurality of electrical phases. Examples of each module 201 may include a plurality of PCB boards 245 ( Fig. 20A-20H). Each PCB plate 245 may include a single electrical phase or a plurality of electrical phases. The PCB plates may be one-piece plates or may include stator segments, as described elsewhere herein.

[0059] In one version, the module 201 and the second module 201 may be configured to be identical to each other. In another version, the module 201 and the second module 201 may differ. For example, the module 201 may differ from the second module 201 in at least one of the following variables: input or output power, number of rotors 233, number of magnets 237, number of stators 41 (see previous drawings), number of PCBs 245, number of PCB layers 47 (see previous drawings), number of traces 49 (see previous drawings), and angular orientation with respect to the axis 235.In some embodiments, one or more of these variables may be varied, for example, to achieve differences in power efficiency, torque, achievable revolutions per minute (RPM), so that different modules 201 may be used to better tailor operation depending on load or other desired operating parameters.

[0060] Some embodiments of the module 201 may include at least one lock 207 ( Fig. 23 and Fig. 24), which is configured to mechanically attach the modules to each other. Fig. 23 shows modules arranged in a nested manner with the locks 207 opened, and Fig. 24 illustrates modules nested with the latches 207 closed. In one example, the latches 207 may be arranged symmetrically with respect to the axis 235. In another version, an upper module (not shown) may be configured to be axially disposed on top of another module, and the upper module may be structurally different from the second module. For example, the upper module 201 may include latches 207 only on its bottom surface and omit such latches 207 on its top surface. As another example, the shaft 209 may extend from the lower module 201 but not from the upper module 201.

[0061] As in the Fig. 21-24, the module 201 may include a splined shaft 209. The module 201 may be mounted on the splined shaft, which may be configured to be mechanically coupled to another module 201.

[0062] Some embodiments may further include a body 213 ( Fig. 26) (also referred to herein as "enclosure"). The body 213 may be configured to contain a plurality of the modules 201 within the body 213 and mount them coaxially. In the illustrated example, the body 213 comprises two halves coupled together with fasteners. In versions where each module 201 comprises a single electrical phase, the body 213 may be configured to hold the modules 201 at a desired electrical phase angle with respect to the axis 235. In versions where the body 213 comprises a plurality of electrical phases, the body 213 may be configured to hold the modules 201 at desired electrical phase angles with respect to the axis 235.

[0063] In other versions, a plurality of bodies 213 may be present. Each body 213 may include mechanical features, such as coupling structures configured to mechanically couple each body 213 to at least one other body 213, and electrical elements configured to electrically couple each body 213 to at least one other body 213. Each body 213 may be configured to be coupled directly or indirectly to at least one other body 213.

[0064] In some generator embodiments, one body (or more than one coupled body) may include a number of electrical phases (such as approximately 4 to 99; e.g., at least 10, 11, 12, 13, 14, 15, or more) of AC output. Therefore, the AC output may function as a DC-like output ripple without being rectified or requiring power conversion. In other versions, such AC output may be rectified.

[0065] Embodiments of a system for providing energy are also disclosed. The system may, for example, include a plurality of modules 201 comprising axial-field rotary energy devices. The modules 201 may be interchangeably connected to configure the system for a desired power output. Each module may be configured based on any of the embodiments described herein. The system may include a generator or a motor. Embodiments of the system may include at least two of the modules 201 that are differently configured. The modules 201 may differ from one another, for example, by at least one of the following variables: input or output power, number of rotors, number of magnets, number of stators, number of PCBs, number of PCB layers, number of coils, and angular orientation with respect to the axis.

[0066] Embodiments of a method for repairing an axial-field rotary energy device are also disclosed. The method may include, for example, the following steps: Providing a body 213 having a plurality of modules 201. Each module 201 may be configured as described for any of the embodiments described herein.The method may also include mechanically and electrically coupling the modules 201 such that the modules 201 are coaxial; operating the axial field energy device; detecting a problem with one of the modules 201 and stopping operation of the axial field energy device; opening the body 213 and detaching the problematic module 201 from all other modules 201 to which the problematic module 201 is attached; installing a replacement module 201 in the body 213 in place of the problematic module 201 and attaching the replacement module 201 to the other modules 201 to which the problematic module 201 was attached; and then operating the axial field energy device again.

[0067] Other embodiments of the method include angularly aligning the modules to at least one desired electrical phase angle with respect to the axis. In another version, the method may include providing a plurality of bodies 213 and mechanically and electrically coupling the bodies 213.

[0068] Still other embodiments of a method of operating an axial-field rotary energy device may include providing an enclosure having a plurality of modules, each module comprising a housing, rotors rotatably mounted to the housing, each rotor comprising an axle and a magnet, stators mounted to the housing coaxial with the rotors, each stator comprising a printed circuit board (PCB) having a coil, each stator consisting of a single electrical phase, and selected stators adjusted at desired phase angles with respect to the axis; mechanically and electrically coupling the modules such that the modules are coaxial within the enclosure; and then operating the axial-field energy device.In other words, setting the individual phase stators at the same phase angle can form a single-phase machine and setting the individual phase stators to varying phase angles can form a multi-phase machine (or with more than 2 phases).

[0069] Optionally, the enclosure and each module may comprise a single electrical phase, and the method may include angularly aligning the modules at a desired electrical phase angle with respect to the axis. The method may include enclosing a plurality of electrical phases, each module comprising a single electrical phase, and angularly aligning the modules at desired electrical phase angles with respect to the axis. The enclosure and each module may include a plurality of electrical phases and angularly misaligning the modules at desired electrical phase angles with respect to the axis.

[0070] Some versions of the method may include providing a plurality of bodies, and the method further comprises mechanically and electrically coupling the bodies to form an integrated system. Each module may include a plurality of stators angularly offset from one another with respect to the axis at desired electrical phase angles. In one example, each stator consists of only one PCB. In other examples, each stator includes two or more PCBs coupled together to form each stator. In yet another version, the enclosure may have a number of electrical phases of alternating current (AC) output substantially consistent with a clean, direct current (DC)-like ripple without power conversion, as described herein.

[0071] In other versions, a method for repairing an axial-field rotating energy device may include providing a plurality of bodies coupled together, each enclosure having a plurality of modules, each module comprising a housing, a rotor rotatably mounted to the housing, the rotor comprising an axle and a magnet, a stator coaxially mounted with the rotor to the housing, and the stator comprising a printed circuit board (PCB); mechanically and electrically coupling the modules; operating the axial-field rotating energy device; detecting a problem with a first module in a first enclosure and stopping operation of the axial-field rotating energy device; opening the first enclosure and disassembling the first module from the first enclosure and any other modules to which the first module is attached;Installing a second module in the first enclosure in place of the first module and attaching the second module to any other module to which the first module was attached; and then re-operating the axial-field rotational energy device.;

[0072] Embodiments of each module can have only one orientation within the enclosure, so that each module can be installed or uninstalled in a unique manner relative to the enclosure. The purpose of such designs is to prevent the person working on the system from reinstalling new modules in an incorrect position within an existing system. Installation can only be done in one orientation. The procedure can be performed while the operation of the AFRED is interrupted, and treatment of the first module takes place without interrupting any other module and without altering or affecting any other module.

[0073] Fig. Figure 27 illustrates another embodiment of a PCB stator 311 for an axial-field rotating energy device, such as those disclosed herein. The PCB stator 311 includes a substrate having one or more conductive traces 313 that are electrically conductive. In the version shown, the PCB stator 311 includes eight coils of conductive traces 313. Furthermore, the PCB stator 311 may include more than one layer of conductive traces 313. The conductive traces 313 on each layer are coplanar with the layer. Furthermore, the conductive traces 313 are arranged about a central axis 315 on the PCB stator.

[0074] Fig. 28 is an enlarged plan view of a portion of the PCB stator of Fig. 27. In the embodiment shown, each trace 313 includes radial sections 317 (relative to axis 315) and end turns 319 extending between the radial sections 317. Each trace 313 may be separated by a slot 321. In some versions, only radial sections 317 include slots 321. The slots 321 can help reduce eddy current losses during operation. Eddy currents oppose the magnetic field during operation. Reducing eddy currents increases the magnetic strength and increases the efficiency of the system. In contrast, wide traces can allow eddy currents to build up. The slots in the traces 313 can reduce the possibility of eddy currents forming. The slots can force current to flow more effectively through the traces 313.

[0075] The axial-field rotating energy device may comprise a "smart machine" that includes one or more sensors integrated therein. In some embodiments, such a sensor may be configured to monitor, detect, or generate data related to the operation of the axial-field rotating energy device. In certain embodiments, the operating data may include at least one of power, temperature, speed, rotor position, or vibration data.

[0076] Versions of the axial-field rotating energy device may comprise an integrated machine including one or more control circuits integrated therein. Other versions of the axial-field rotating energy device may comprise a fully integrated machine including one or more sensors and one or more control circuits integrated therein. One or more sensors and / or control circuits may, for example, be integrated into the PCB and / or integrated into the housing. For motor embodiments, these control circuits may be used to control or drive the machine. In some motor embodiments, such control circuitry may, for example, include an input coupled to receive an external power source and may also include an output coupled to provide a current to flow through one or more stator coils.In some embodiments, the control circuit is configured to provide torque and / or torque commands to the machine. In some generator embodiments, such a control circuit may include an input coupled to receive the current flowing through the coil and may also include an output coupled to generate an external power source.

[0077] For example, one or more sensors and / or control circuits may be integrated into the PCB stator 311. Fig. Figure 29 shows another exemplary stator 340 having integrated sensors (e.g., 342, 346) attached to its topmost PCB layer 47. Such a sensor 342 is coupled to a secondary coil 344, which can be used to send / receive data to / from an external device and can also be used to couple power to the sensor 342. In some embodiments, the secondary coil can be configured to utilize a magnetic current developed during operation to provide power to the sensor 342. In some embodiments, the secondary coil can be configured to receive inductively coupled power from an external coil (not shown).The secondary coil 344 may also be referred to herein as a micro coil or miniature coil, as such a secondary coil may, in some embodiments, be substantially smaller than a stator coil 49, but no relative size inference is intended. Rather, such a secondary coil 344 is distinct from the stator coils 49 that interact with the rotor magnets, as described above. Such a secondary coil integrated with the PCB stator 311 may, in certain embodiments, be disposed on the PCB stator 311 (e.g., fabricated on or attached to its topmost PCB layer 47). Such a secondary coil integrated with the PCB stator 311 may, in certain embodiments, be disposed within the PCB stator 311 (i.e., embedded therein). In some embodiments, the secondary coil 344 provides power to a sensor connected thereto.Such coupled power may be primary or auxiliary power for the sensor.

[0078] The sensor 346 is coupled to the first terminal 51 for one of the conductive traces 49 on the upper PCB layer 47 and can detect an operating parameter, such as voltage or temperature at that location, and can also be driven by the coil attached thereto (e.g., one of the coils 49). The sensor 348 is coupled to an external terminal 350 and can also detect an operating parameter, such as voltage or temperature at that location, and can also be driven by the voltage coupled to the external terminal 350. The sensor 350 is arranged on an outer edge of the PCB stator 340 but is not coupled to a conductor of the PCB layer 47.

[0079] In some embodiments, such a sensor may be embedded directly in one of the coils 49 and may be electrically driven directly by the coil 49. In some embodiments, such a sensor may be driven by and connected to the coil 49 through a separate connection disposed on or within the PCB layer 47, such as the connection between the first terminal 51 and the sensor 346. Such a connection may be disposed on the PCB layer 47 or may be disposed within the PCB (e.g., on an inner layer of the PCB). In other embodiments, the sensor and / or circuitry may receive power from an external power source. One type of external power source may be, for example, a conventional electrical wall outlet that may be coupled to the housing of the motor or generator.

[0080] The sensors can provide operators of generator or motor products with real-time operating data, as well as, in certain embodiments, predictive data about various parameters of the product. This can include how the equipment is operating and how and when to schedule maintenance. Such information can reduce product downtime and increase product lifespan. In some embodiments, the sensor can be integrated within the housing. In some examples, the sensors can be embedded within the PCB stator 340, as in Fig. 30 (e.g., sensors 362, 366, 368, 372 and coil 364).

[0081] An example of a sensor for this application is a Hall-effect sensor. Hall-effect sensors are used for proximity switching, positioning, speed detection, and current sensing applications. In its simplest form, the Hall-effect sensor operates as an analog converter that directly feeds back a voltage.

[0082] Another example of a sensor is an optical sensor. Optical sensors can measure the intensity of electromagnetic waves in a wavelength range between UV light and near-infrared light. The basic measuring device is a photodiode. Combining a photodiode with electronics creates a pixel. In one example, the optical sensor may include an optical encoder that uses optics to measure or detect the positions of the magnetic rotor.

[0083] Another example of a sensor is a thermocouple sensor for measuring temperature. Thermocouples consist of two wire legs made of different metals. The wire legs are welded together at one end, forming a junction. The junction is located where the temperature is measured. When the junction detects a change in temperature, a voltage is generated.

[0084] Another optional sensor is a tachometer. A tachometer is an electromechanical device used to measure acceleration forces. Such forces can be static, such as continuous gravity, or, as is the case with many mobile devices, dynamic, used to detect motion or vibration. Acceleration is the measurement of the change in speed or rotational speed divided by time.

[0085] A gyroscopic sensor, which functions like a gyroscope, can also be used in these systems. Gyroscopic sensors can be used to provide stability or maintain a reference heading in navigation systems, autopilots, and stabilizers.

[0086] The PCB stator 340 may also include a torque sensor. A torque sensor, torque transducer, or torque meter is a device for measuring and recording torque in a rotating system, such as an axial-field rotary energy device.

[0087] Another optional sensor is a vibration sensor. Vibration sensors can measure, display, and analyze linear velocity, displacement, proximity, or acceleration. Vibration, even low vibration, can be a clear indicator of a machine's condition.

[0088] In various embodiments, the Fig. 29 and Fig. 30 may also represent control circuits integrated into the PCB stator 345. Such control circuits may be arranged on a surface of the PCB (analogous to the Fig. 29), be arranged within the PCB (ie embedded in it) (analogous to the sensors shown in Fig. 30 shown sensors) and / or be integrated in or within the housing (e.g. housing 203 in Fig. 18).

[0089] In some generator embodiments, the control circuit may implement power conversion from an AC voltage developed in the starter coils to an external desired power source (e.g., an AC voltage of a different magnitude than the coil voltage, a DC voltage developed by rectifying the coil voltage). In some motor embodiments, the control circuit may implement an integrated drive circuit that provides desired AC waveforms to the stator coils to drive the motor. In some examples, the integrated drive may be a variable frequency drive (VFD) and may be integrated in the same housing as the motor. The sensors and / or circuitry disclosed herein may be wireless or hardwired to any element of the housing, on, or within the housing. Alternatively, the sensors and / or circuitry may be remote relative to the housing.

[0090] Each of these sensors and control circuits may include wireless communication circuitry configured to communicate with an external device over a wireless network environment. Such wireless communication may be unidirectional or bidirectional and may be useful for monitoring a status of the system, operating the system, communicating predictive data, etc. Wireless communication over the network may be performed using, for example, at least one of Long-Term Evolution (LTE), LTE-Advanced (LTE-A), Code Division Multiple Access (CDMA), Wideband CDMA (WCDMA), a Universal Mobile Telecommunications System (UMTS), Wireless Broadband (WiBro), or a Global System for Mobile Communications (GSM) as the cellular communication protocol.

[0091] Additionally or alternatively, the wireless communication may, for example, include short-range communication. The short-range communication may, for example, be performed by at least one of Wireless Fidelity (WiFi), Bluetooth®, Near Field Communication (NFC), or GNSS. GNSS may, for example, include at least one of a Global Positioning System (GPS), a Glonass® Global Navigation Satellite System, a Beidou® Navigation Satellite System, or Galileo®, the European Global Satellite-Based Navigation System. In the present disclosure, the terms 'GPS' and 'GNSS' are interchangeable. The network may be a communications network, for example, at least one of a computer network (e.g., Local Area Network (LAN) or Wide Area Network (WAN)), the Internet, or a telephone network.

[0092] In certain embodiments, such a wireless communication circuit may be coupled to a secondary coil (e.g., secondary coil 344) to communicate telemetry information, such as the operational data described above.

[0093] The Fig. 31 and Fig. 32 show one embodiment of an arrangement for mechanically coupling stator segments 380 together to form a stator. A clamp 382 slides over portions of a mounting surface 381 on two adjacent stator segments 380, which is secured by a pair of nuts on each of the two bolts (e.g., bolt 384). The clamp 382 includes an alignment tab 392 that can be positioned in a sidewall slot 214, as described above. The edge of the inner diameter of the two adjacent stator segments 380 slides into a profiled rotor spacer 390 in the form of an annular ring. In some embodiments, this rotor spacer 390 can slide on a thrust bearing, with the rotor allowing the rotor spacer 390 and the stator to remain stationary while the rotor rotates. In other embodiments, a rotor spacer as described above (e.g., Fig. 18, 20A-20H) fit within the open center of the profiled rotor spacer 390.

[0094] An electrical connection between adjacent stator segments 380, 381 may be implemented using a wire 387 between respective circuits 386, 388. The circuit 386 may connect to a conductive trace on the upper layer (or another layer using a via) of the stator segment 380. Likewise, the circuit 388 may connect to a conductive trace of any layer of the stator segment 381. Such circuits 386, 388 may include any of the sensors described above ( Fig.29-30), but may also only provide an electrical connection from the respective PCB to the wire 387. In other embodiments, an electrical connection may also be made via the mounting surface of the PCB, which is a conductive material and is connected to the coil, and the subsequent coupling of these components via the clamp, which may also include conductive material on its inner surface.

[0095] An electrical connection can also be made using the clamp 382 in conjunction with an electrically conductive mounting surface 383. If the mounting surface 383 is continuous and uninterrupted, the clamps 382 can provide a common electrical connection around the circumference of the stator. If such mounting surfaces are not continuous and broken into two parts (as shown by the dashed lines), each part coupled to a respective terminal of a conductive trace on that segment, the clamps 382 can connect serially to such stator segments.

[0096] The axial-field rotary energy device is suitable for many applications. The PCB stator 340 can be configured for a desired performance criterion and can be a factor for devices such as permanent magnet generators and motors. Such designs are lighter, easier to manufacture, easier to maintain, and can exhibit higher efficiency.

[0097] Examples of permanent magnet generator (PMG) applications may include a wind turbine generator, a microgenerator application, a direct drive permanent magnet generator, a steam turbine generator, a hydrogenerator, a heat generator, a gas generator, a wood fire generator, a coal generator, a high frequency generator (e.g., frequency above 60 Hz), a portable generator, an auxiliary power unit, motor vehicles, an AC generator, a regenerative braking device, a PCB stator for a regenerative braking device, an emergency power generator or a standby power generation device, a PMG for emergency or standby power generation, a PMG for military use, and a PMG for aerospace use.

[0098] In other embodiments, examples of a permanent magnet motor (PMM) may include an AC motor, a DC motor, a servo motor, a stepper motor, a drone motor, a household appliance, a fan motor, a microwave oven, a vacuum machine, an automobile, an electric vehicle powertrain, industrial machinery, a production line motor, enabled Internet of Things (IOT) sensors, heating, ventilation, and air conditioning (HVAC), an HVAC fan motor, laboratory equipment, precision motors, military, autonomous vehicle motors, aerospace, and aircraft engines.

Claims

[1] An axial field rotational energy device comprising: a rotor (33) comprising a rotation axis (35) and a magnet (37); and a stator (141) coaxial with the rotor (33), the stator (141) comprising a plurality of stator segments (142) coupled together about the axis, each stator segment (142) comprising a printed circuit board, PCB, (145) having a plurality of PCB layers (47), wherein the PCB layers (47) form at least two layer pairs (57). wherein the two PCB layers (47) of each layer pair (57) are electrically coupled to one another via vias (155, 159), and wherein each PCB layer (47) comprises a plurality of coils (149) that are coplanar and angularly spaced from one another with respect to the rotation axis (35), wherein each coil (149) is wound from a partially continuous conductive trace and is concentric in a single plane from an outermost coil section to a concentric innermost coil section, wherein the coils (149) in adjacent PCB layers (47) are circumferentially aligned relative to the axis to define symmetrical stacks of coils (149) in the axial direction, and each stator segment (142) comprises only one electrical phase, wherein each coil (149) has a first terminal (51) at the outer edge of the coil (149) and a second terminal (53) in the center of the coil (149), wherein a first via (55.1) couples the second terminal (53) of a first coil (49.11) of the plurality of coils (149) of a first PCB layer (47.1) of a layer pair (57.1) to a second terminal (53) of a second coil (49.21) of the plurality of coils (149) of a second PCB layer (47.2) of the layer pair (57.1) adjacent to the first coil, and wherein a second via (55.2) couples the first terminal (51) of the second coil (49.21) of the plurality of coils (149) of the second PCB layer (47.2) of the layer pair (57.1) to a first terminal (51) of another coil (49.12) of the plurality of coils (149) of the first PCB layer (47.1) of the layer pair (57.1) adjacent to the first coil. [2] The axial field rotary energy device of claim 1, wherein the stator (141) consists of only one electrical phase. [3] The axial field rotary energy device of claim 1, wherein the stator (141) comprises a plurality of electrical phases. [4] An axial field rotary energy device according to any preceding claim, wherein the coils (149) are identical to one another. [5] An axial field rotary energy device according to any preceding claim, wherein each coil comprises radial conductive traces extending from approximately an inner diameter of the PCB to approximately an outer diameter of the PCB. [6] An axial field rotary energy device according to any preceding claim, wherein each coil comprises only linear traces continuous from an outermost trace to a concentric innermost trace, no trace of the PCB layers is non-linear, and each coil comprises corners to connect the only linear traces. [7] The axial field rotary energy device of any preceding claim, wherein each PCB layer comprises a surface area of ​​the PCB layer, the coils on each PCB layer having a coil surface area that is in a range of at least about 75% to about 99% of the surface area of ​​the PCB layer. [8] An axial field rotary energy device according to claim 1, comprising: a plurality of rotors including a rotation axis and a plurality of magnets; a plurality of stators arranged coaxially with the rotors, wherein at least one rotor, at least one stator and at least one magnet are arranged within a housing of a module of the axial field rotary energy device and surrounded thereby. [9] An axial field rotational energy device comprising: a rotor (33) comprising a rotation axis (35) and a magnet (37); a stator (141) arranged coaxially with the rotor (33), the stator (141) comprising a plurality of stator segments (142) coupled around the axis, each stator segment (142) comprising a printed circuit board (PCB) having a plurality of PCB layers (47), the PCB layers (47) forming at least two layer pairs (57), the two PCB layers (47) of each layer pair (57) being electrically coupled to one another via vias (155, 159), and each PCB layer (47) comprising a plurality of coils (149), the PCB layers (47) being spaced apart from one another in the axial direction, and each PCB layer (47) being configured for only one electrical phase; and the coils (149) in each PCB layer (47) are coplanar and angularly spaced from one another about the axis, each coil (149) being wound from a sectionally continuous conductor track and being concentric in a single plane from an outermost coil section to a concentric innermost coil section, and the coils (149) in adjacent PCB layers (47) being circumferentially aligned relative to the axis to define symmetrical stacks of coils (149) in the axial direction, each coil (149) having a first terminal (51) at the outer edge of the coil (149) and a second terminal (53) in the center of the coil (149), wherein a first via (55.1) couples the second terminal (53) of a first coil (49.11) of the plurality of coils (149) of a first PCB layer (47.1) of a layer pair (57.1) to a second terminal (53) of a second coil (49.21) of the plurality of coils (149) of a second PCB layer (47.2) of the layer pair (57.1), and wherein a second via (55.2) couples the first terminal (51) of the second coil (49.21) of the plurality of coils (149) of the second PCB layer (47.2) of the layer pair (57.1) to a first terminal (51) of another coil (49.12) of the plurality of coils (149) of the first PCB layer (47.1) of the layer pair (57.1), adjacent to the first coil. [10] An axial field rotary energy device according to claim 9, wherein the stator (141) consists of only one electrical phase. [11] The axial field rotary energy device of claim 9, wherein the stator (141) comprises a plurality of electrical phases. [12] The axial field rotary energy device of claim 9, wherein the coils on each PCB layer on each stator segment are configured for the single electrical phase. [13] The axial field rotary energy device of claim 9, wherein the axial field rotary energy device consists of a single electrical phase. [14] The axial field rotary energy device of claim 9, wherein the rotor includes slots extending through the rotor. [15] An axial field rotary energy device according to claim 14, wherein the slots are angled with respect to the axis and not merely vertical. [16] The axial field rotary energy device of claim 15, wherein the angles of the slots have constant slopes to allow cooling airflow within the axial field rotary energy device. [17] The axial field rotary energy device of claim 16, further comprising a rotor spacer having additional slots.

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