A motor

Abstract

A motor, including a stator assembly including a plurality of stator rings, the stator assembly defining a cavity, and at least one rotor assembly, each rotor assembly including a rotor arranged on an axle, each axle having a longitudinal axis, each rotor assembly rotatable about the longitudinal axis of the respective axle, wherein each stator ring has a plurality of stator magnets, wherein each rotor has a plurality of rotor magnets, wherein each rotor is located within the cavity, and wherein each rotor is operably associated with one of the plurality the stator rings.

Description

[0001] A MOTOR

[0002] FIELD OF INVENTION

[0003] The present invention relates to a motor. The present invention has a particular but not exclusive application for a magnet-assisted motor. The patent specification describes this application, but it is by way of example only and the invention is not limited to this application.

[0004] BACKGROUND OF THE INVENTION

[0005] Modern electrical devices often incorporate permanent magnets to generate electricity or mechanical power. The main advantage of a permanent magnet over an electromagnet is that a permanent magnet does not require a continuous supply of electrical energy to maintain a persistent magnetic field. This enables more efficient energy usage, particularly in applications where power consumption and heat generation must be minimized.

[0006] Known in the art is the use of permanent magnets in motors, which are commonly called permanent magnet motors. A conventional permanent magnet motor is an AC motor that uses magnets embedded into or attached to the surface of the motor’s rotor. The magnets generate a fixed magnetic field (or motor flux), eliminating the need for the stator to induce rotor magnetization. Instead, alternating current supplied to the stator windings generates a rotating magnetic field that interacts with the rotor magnets, producing torque and mechanical motion. These motors offer several advantages over traditional induction motors, including higher torque density, improved efficiency, and better dynamic performance, making them suitable for applications in electric vehicles, robotics, industrial automation, and consumer electronics.

[0007] However, the arrangement and interaction of permanent magnets within these motors are critical to performance. Depending on their orientation and position relative to the stator field, the magnets can produce undesirable effects, such as cogging torque, eddy current losses, and opposing magnetic forces. In particular, permanent magnet motors can suffer from performance inefficiencies when magnets are in repulsion against the intended direction of rotation. This phenomenon can result in torque ripple, reduced efficiency, and mechanical stress within the rotor structure. One known method for mitigating such adverse effects is through precise control of the stator's electromagnetic field. By dynamically modulating the excitation current supplied to the stator windings, the system can produce strong or weak magnetic flux at specific intervals, thus influencing the torque profile to minimize reverse-direction repulsion. While this approach is theoretically effective, it requires complex control algorithms and high-speed power electronics capable of fine-grained timing and feedback response. As a result, implementation can be both challenging and cost-prohibitive, particularly in applications demanding low-cost or compact design solutions.

[0008] OBJECT OF THE INVENTION

[0009] It is an object of the present invention to overcome or at least alleviate one or more of the above mentioned problems with magnet-assisted motors and / or provide the consumer with a useful or commercial choice.

[0010] SUMMARY OF THE INVENTION

[0011] In one aspect, the present invention broadly resides in a motor, including a stator assembly including a plurality of stator rings, the stator assembly defining a cavity; and at least one rotor assembly, each rotor assembly including a rotor arranged on an axle, each axle having a longitudinal axis, each rotor assembly rotatable about the longitudinal axis of the respective axle, wherein each stator ring has a plurality of stator magnets; wherein each rotor has a plurality of rotor magnets; wherein each rotor is located within the cavity; and wherein each rotor is operably associated with one of the plurality the stator rings.

[0012] Preferably the at least one rotor assembly is a plurality of rotor assemblies. In another embodiment the at least one rotor assembly is a single rotor assembly.

[0013] In another aspect, the present invention resides in a motor, including a stator assembly including a plurality of stator rings, the stator assembly defining a cavity; and a plurality of rotor assemblies, each rotor assembly including a rotor arranged on an axle, each axle having a longitudinal axis, each rotor assembly rotatable about the longitudinal axis of the respective axle, wherein each stator ring has a plurality of stator magnets; wherein each rotor has a plurality of rotor magnets; wherein each rotor is located within the cavity; and wherein each rotor is operably associated with one of the plurality the stator rings.

[0014] In one embodiment, each rotor preferably has a plurality of rotor layers, and wherein the plurality of rotor magnets are arranged on each rotor layer. Preferably, each of the stator rings is operably associated with only one rotor layer per rotor assembly. Preferably, each of the plurality of rotor layers is coplanar with the corresponding operably associated stator ring.

[0015] In one embodiment, each rotor assembly preferably includes a plurality of planar rotors. Preferably, each of the stator rings is operably associated with only one planar rotor per rotor assembly. Preferably, each of the plurality of planar rotors is coplanar with the corresponding operably associated stator ring.

[0016] Preferably, the plurality of stator rings are arranged in series, with each stator ring being adjacent to at least one other stator ring.

[0017] Preferably, the plurality of planar rotors are arranged in series, with each planar rotor being adjacent to at least one other planar rotor.

[0018] In an embodiment wherein each rotor includes a plurality of rotor layers, each rotor layer is preferably rotationally offset around the longitudinal axis from an adjacent rotor layer of the same rotor assembly. Preferably, each rotor layer is rotationally offset around the longitudinal axis from an adjacent rotor layer of the same rotor assembly by substantially 1 degree to 40 degrees. More preferably, each rotor layer is rotationally offset around the longitudinal axis from an adjacent rotor layer of the same rotor assembly by substantially 3 degrees to 10 degrees. Preferably, each rotor layer is rotationally offset around the longitudinal axis from an adjacent rotor layer of the same rotor assembly such that the plurality of lobes of one rotor layer is rotationally offset to the plurality of lobes of another rotor layer.

[0019] In an embodiment wherein each rotor includes a plurality of rotor layers, a first rotor layer of at least one of the plurality of rotor assemblies preferably has a first orientation and each adjacent rotor layer in series is rotationally offset from the preceding rotor layer around the longitudinal axis. Preferably, each rotor layer which is rotational offset along the rotor assembly is offset in the same rotational direction as each other offset rotor layer.

[0020] In an embodiment wherein each rotor includes a plurality of rotor layers, with respect to at least one of the plurality of rotor assemblies wherein the rotor assembly has a first rotor layer, preferably each the nthrotor in series from the first rotor layer is rotationally offset around the longitudinal axis from the first rotor layer by n*x, wherein x is a predetermined amount.

[0021] In an embodiment wherein each rotor assembly includes a plurality of rotor layers, each of the plurality of rotor magnets preferably has a proximal end closest to the axle of the corresponding rotor layer and a distal end furthest from the axle of the corresponding rotor layer.

[0022] In an embodiment wherein each rotor assembly includes a plurality of planar rotors, each planar rotor is preferably rotationally offset around the longitudinal axis from an adjacent planar rotor of the same rotor assembly. Preferably, each planar rotor is rotationally offset around the longitudinal axis from an adjacent planar rotor of the same rotor assembly by substantially 1 degree to 40 degrees. More preferably, each planar rotor is rotationally offset around the longitudinal axis from an adjacent planar rotor of the same rotor assembly by substantially 3 degrees to 10 degrees. Preferably, each planar rotor is rotationally offset around the longitudinal axis from an adjacent planar rotor of the same rotor assembly such that the plurality of lobes of one planar rotor is rotationally offset to the plurality of lobes of another planar rotor.

[0023] In an embodiment wherein each rotor assembly includes a plurality of planar rotors, a first planar rotor of at least one of the plurality of rotor assemblies preferably has a first orientation and each adjacent planar rotor in series is rotationally offset from the preceding planar rotor around the longitudinal axis. Preferably, each planar rotor which is rotational offset along the rotor assembly is offset in the same rotational direction as each other offset planar rotor.

[0024] In an embodiment wherein each rotor assembly includes a plurality of planar rotors, with respect to at least one of the plurality of rotor assemblies wherein the rotor assembly has a first planar rotor, preferably each the nthrotor in series from the first planar rotor is rotationally offset around the longitudinal axis from the first planar rotor by n*x, wherein x is a predetermined amount. In an embodiment wherein each rotor assembly includes a plurality of planar rotors, each of the plurality of rotor magnets preferably has a proximal end closest to the axle of the corresponding planar rotor and a distal end furthest from the axle of the corresponding planar rotor.

[0025] Preferably, each of the plurality of rotor magnets has an operative end. Preferably, the distal end is the operative end of the rotor magnet.

[0026] Preferably, the distal end of one or more of the plurality of rotor magnets is shaped to produce a magnetic force of a desired shape. In one embodiment, the distal end of one or more of the plurality of rotor magnets has a convex shape. In another embodiment, the distal end of one or more of the plurality of rotor magnets has a flat shape.

[0027] Preferably, each rotor assembly produces a helical magnetic field.

[0028] Preferably, each of the of the plurality of stator magnets has a proximal end closest to the cavity and a distal end furthest from the cavity. Preferably, each of the of the plurality of stator magnets has an operative end. Preferably, the proximal end is the operative end of the stator magnet. Preferably, each stator magnet is oriented such that the proximal end leads the distal end in the direction of rotation of the adjacent rotor assembly.

[0029] Preferably, the proximal end of one or more of the plurality of stator magnets is shaped to produce a magnetic force of a desired shape. In one embodiment, the proximal end of one or more of the plurality of stator magnets has a convex shape. In another embodiment, the proximal end of one or more of the plurality of stator magnets has a flat shape.

[0030] Preferably, at least one of the plurality of rotor magnets is shaped to concentrate magnetic force in a specific area. In one embodiment, one or more of the plurality of rotor magnets have external ribs to concentrate magnetic force in a specific area.

[0031] Preferably, at least one of the plurality of stator magnets is shaped to concentrate magnetic force in a specific area. In one embodiment, one or more of the plurality of stator magnets as external ribs to concentrate magnetic force in a specific area.

[0032] In an embodiment wherein each rotor includes a plurality of rotor layers, the plurality of rotor magnets and the plurality of stator magnets are preferably arranged such that each rotor layer is out of phase with each associated stator ring. In an embodiment wherein each rotor assembly includes a plurality of planar rotors, the plurality of rotor magnets and the plurality of stator magnets are preferably arranged such that each planar rotor is out of phase with each associated stator ring.

[0033] Preferably, the number and alignment of the plurality of rotor magnets and the plurality of stator magnets is such to prevent magnetic lock of the rotor assemblies with the stator assembly in the rotation cycle. Preferably, the number and alignment of the plurality of rotor magnets and the plurality of stator magnets is such that at least one set of rotor magnet and stator magnet are in maximum repulsion at any time.

[0034] In an embodiment wherein each rotor assembly includes a plurality of planar rotors, each planar rotor preferably has a uniform shape.

[0035] In an embodiment wherein each rotor includes a plurality of rotor layers, each rotor layer preferably has a uniform shape.

[0036] Preferably, each stator ring has a uniform shape.

[0037] Preferably, each of the plurality of stator rings is substantially oval-shaped. In one embodiment where there are three rotor assemblies, each of the plurality of stator rings is substantially triangle-shaped.

[0038] Preferably, the cavity shaped to accommodate the plurality of rotor assemblies. Preferably, the cavity is a prism with a substantially oval-shaped cross-section. In one embodiment where there are three rotor assemblies, the cavity is preferably a prism with a substantially triangular-shaped cross-section.

[0039] Preferably, the cavity defines a substantially cylindrical volumes for each of the rotor assemblies to be located within. Preferably, the cylindrical volumes overlap.

[0040] Preferably, each of the plurality of stator rings has an inner wall which defines a portion of the cavity. Preferably, the plurality of stator magnets are arrayed such that the operative end of each stator magnet is at or adjacent the inner wall of the respective stator ring.

[0041] In an embodiment wherein each rotor includes a plurality of rotor layers, the number of rotor magnets of a rotor layer and the number of stator magnets of a stator ring associated with the rotor layer are preferably not the same.

[0042] In an embodiment wherein each rotor assembly includes a plurality of planar rotors, the number of rotor magnets of a planar rotor and the number of stator magnets of a stator ring associated with the planar rotor are preferably not the same.

[0043] In an embodiment wherein each rotor includes a plurality of rotor layers, each of the plurality of stator rings preferably has a prime number of stator magnets. In an embodiment where there are two rotor assemblies, the plurality of stator magnets are arrayed so that n stator magnets are arranged about a first rotor layer and n-1 stator magnets are arranged about a second rotor layer. In an embodiment where there are two rotor assemblies, the plurality of stator magnets are arrayed in a semi-circle arrangement about each rotor assembly. Preferably, the number of rotor magnets in a rotor layer does not share a denominator with the number of stator magnets arranged about the rotor layer.

[0044] In an embodiment wherein each rotor assembly includes a plurality of planar rotors, each of the plurality of stator rings preferably has a prime number of stator magnets. In an embodiment where there are two rotor assemblies, the plurality of stator magnets are arrayed so that n stator magnets are arranged about a first planar rotor and n-1 stator magnets are arranged about a second planar rotor. In an embodiment where there are two rotor assemblies, the plurality of stator magnets are arrayed in a semi-circle arrangement about each rotor assembly. Preferably, the number of rotor magnets in a planar rotor does not share a denominator with the number of stator magnets arranged about the planar rotor.

[0045] In an embodiment wherein each rotor includes a plurality of rotor layers, each rotor layer preferably has a polygonal shape. Preferably, each rotor layer has a plurality of lobes. Preferably the number of lobes coincides with a prime number of three or more.

[0046] In an embodiment wherein each rotor assembly includes a plurality of planar rotors, each planar rotor preferably has a polygonal shape. Preferably, each planar rotor has a plurality of lobes. Preferably, the number of lobes coincides with a prime number of three or more.

[0047] In an embodiment wherein each rotor includes a plurality of rotor layers, the plurality of rotor magnets is preferably arrayed such that at least one rotor magnet is positioned at each vertex of the polygonal shape of each rotor layer. Preferably, the number of rotor magnets at each vertex of the polygonal shape of each rotor is the same. In one embodiment, the plurality of rotor magnets are arrayed such that rotor magnets are positioned at each vertex of the polygonal shape of each rotor layer. In one embodiment the plurality of rotor magnets are arrayed such that pairs of rotor magnets are positioned at each vertex of the polygonal shape of each rotor layer, each of the two rotor magnets are arranged such that one rotor magnet leads the other in a direction of rotation of the rotor layer. Preferably, each first of the two rotor magnets in a leading direction is more powerful than the second of the two rotor magnets.

[0048] In an embodiment wherein each rotor includes a plurality of rotor layers, the plurality of rotor magnets is preferably arrayed such that at least one rotor magnet is positioned at each of the plurality of lobes of each rotor layer.

[0049] In an embodiment wherein each rotor assembly includes a plurality of planar rotors, the plurality of rotor magnets is preferably arrayed such that at least one rotor magnet is positioned at each vertex of the polygonal shape of each planar rotor. Preferably, the number of rotor magnets at each vertex of the polygonal shape of each planar rotor is the same. In one embodiment, the plurality of rotor magnets is arrayed such that rotor magnets are positioned at each vertex of the polygonal shape of each planar rotor. In one embodiment the plurality of rotor magnets are arrayed such that pairs of rotor magnets are positioned at each vertex of the polygonal shape of each planar rotor, each of the two rotor magnets are arranged such that one rotor magnet leads the other in a direction of rotation of the planar rotor. Preferably, each first of the two rotor magnets in a leading direction is more powerful than the second of the two rotor magnets.

[0050] In an embodiment wherein each rotor assembly includes a plurality of planar rotors, the plurality of rotor magnets is preferably arrayed such that at least one rotor magnet is positioned at each of the plurality of lobes of each rotor layer.

[0051] Preferably, the arrangement of the rotor assemblies and the stator assembly and the corresponding rotor magnets and stator magnets is such that during operation at any time at least one rotor magnet is in maximum repulsion with a stator magnet. In a preferred embodiment each of the plurality of stator rings preferably has a prime number of stator magnets, the arrangement of the rotor assemblies and the stator assembly and the corresponding rotor magnets and stator magnets is such that during operation at any time at least one rotor magnet is in maximum repulsion with a stator magnet.

[0052] In one embodiment, a first of the plurality of rotor assemblies is preferably configured to rotate in a first direction with respect to the longitudinal axis and a second of the plurality of rotor assemblies is preferably configured to rotate in a second direction. Preferably, the first direction and the second direction are opposite directions of rotation with respect to the corresponding longitudinal axis of each of the plurality of rotor assemblies. For example, the first direction is clockwise and the second direction is anticlockwise. In another embodiment, a first of the plurality of rotor assemblies is preferably configured to rotate in a first direction and a second of the plurality of rotor assemblies is preferably configured to also rotate in the first direction. Preferably, the directions of rotation of each of the plurality of rotor assemblies are the same with respect to the corresponding longitudinal axis of each of the plurality of rotor assemblies. For example, the direction of rotation for the first and second of the plurality of rotor assemblies is clockwise.

[0053] In one embodiment the motor has two rotor assemblies, wherein each rotor assembly configured to rotate in the same direction of rotation with respect to their corresponding longitudinal axis. In another embodiment, the motor has three rotor assemblies, wherein each rotor assembly configured to rotate in the same direction of rotation with respect to their corresponding longitudinal axis.

[0054] In an embodiment wherein each rotor includes a plurality of rotor layers, a planar rotor of one of the plurality of rotor assemblies is preferably configured to intermesh with a planar rotor of another of the plurality of rotor assemblies. Preferably, intermeshing planar rotors do not contact one another.

[0055] In an embodiment wherein each rotor assembly includes a plurality of planar rotors, a planar rotor of one of the plurality of rotor assemblies is preferably configured to intermesh with a planar rotor of another of the plurality of rotor assemblies. Preferably, intermeshing planar rotors do not contact one another.

[0056] Preferably, each rotor assembly has a toothed gear on each respective axle. Preferably, the toothed gear on one rotor assembly intermeshes with a toothed gear on an adjacent rotor assembly. Preferably, the intermeshing toothed gears are configured to allow the corresponding rotor assemblies to rotate while the planar rotors are intermeshed without the planar rotors contacting one another.

[0057] Preferably, each stator ring has a different number of stator magnets to each adjacent stator ring. In one embodiment, the plurality of stator rings includes at least one stator ring with a first number of stator magnets and at least one stator ring with a second number of stator magnets, wherein the plurality of stator rings is arranged such that each stator ring with a first number of stator magnets is positioned adjacent one or more of the at least one stator ring with a second number of stator magnets.

[0058] In an embodiment wherein each rotor includes a plurality of rotor layers, each rotor layer preferably has a different number of rotor magnets to number of stator magnets of the associated stator ring. In an embodiment wherein each rotor assembly includes a plurality of planar rotors, each planar rotor preferably has a different number of rotor magnets to number of stator magnets of the associated stator ring.

[0059] In an embodiment wherein each rotor includes a plurality of rotor layers, each stator ring preferably has a different number of stator magnets to number of rotor magnets of each associated rotor layer.

[0060] In an embodiment wherein each rotor assembly includes a plurality of planar rotors, each stator ring preferably has a different number of stator magnets to number of rotor magnets of each associated planar rotor.

[0061] Preferably, each rotor magnet is elongate. Preferably, each rotor magnet has a longitudinal axis. In one embodiment, each of the plurality of rotor magnets are arranged radially within the rotor assembly. In an embodiment wherein each rotor includes a plurality of rotor layers, each of the plurality of rotor magnets are arranged radially within each rotor layer. In an embodiment wherein each rotor assembly includes a plurality of planar rotors, each of the plurality of rotor magnets are arranged radially within each planar rotor. Preferably, each rotor magnet is oriented such that the longitudinal axis of each rotor magnet is coincident with the longitudinal axis of the axle of the corresponding rotor assembly.

[0062] Preferably, each stator magnet is elongate. Preferably, each stator magnet has a longitudinal axis. Preferably, each stator magnet is oriented such that the longitudinal axis of each stator magnet is not coincident with the longitudinal axis of the axle of the adjacent rotor assembly.

[0063] Preferably, when the rotor magnet and the stator magnet are at their closest point the angle between the longitudinal axis of the rotor magnet and the longitudinal axis of the stator is between 20 degrees to 100 degrees. More preferably, when the rotor magnet and the stator magnet are at their closest point the angle between the longitudinal axis of the rotor magnet and the longitudinal axis of the stator is between 45 degrees to 75 degrees. Even more preferably, when the rotor magnet and the stator magnet are at their closest point the angle between the longitudinal axis of the rotor magnet and the longitudinal axis of the stator is approximately 60 degrees.

[0064] Preferably, the maximum distance between a rotor magnet and a stator magnet when the rotor magnet and the stator magnet are at their closest point is 5mm. More preferably, the maximum distance between a rotor magnet and a stator magnet when the rotor magnet and the stator magnet are at their closest point is less than 1 mm. Preferably, the motor has at least two end plates, the at least two end plates and the stator assembly and cavity thereof form a housing with an enclosed chamber. The enclosed chamber can prevent dust particles or debris from entering the cavity and detrimentally affecting the operation of the motor.

[0065] Preferably, the enclosed chamber is maintained at a near vacuum to reduce heat generated by friction.

[0066] In one embodiment, each stator ring is comprised of two or more stator ring pieces. Preferably, the two or more stator ring pieces are connectable to form a stator ring. Preferably, the two or more stator ring pieces are connectable to form a stator ring with pin connectors.

[0067] Preferably, at least one of the plurality of stator magnets is a permanent magnet.

[0068] Preferably, at least one of the plurality of stator magnets is an electromagnet.

[0069] Preferably, at least one of the plurality of rotor magnets is a permanent magnet. Preferably, at least one of the plurality of rotor magnets is an electromagnet.

[0070] Preferably, at least one electromagnet is weaker than at least one permanent magnet.

[0071] Preferably, each permanent magnet is arranged to always be in a repulsion configuration.

[0072] Preferably, each electromagnet has an attraction configuration and a repulsion configuration.

[0073] Preferably, each rotor magnet produces a rotor magnetic field, and each stator magnet produces a stator magnetic field. Preferably, during operation the rotor magnetic field lags the stator magnetic field by 1 degree to 5 degrees and thus produces torque.

[0074] In one embodiment, one or more of the plurality of stator magnets have windings and voltage can be induced in the windings whenever the rotor assemblies are in motion.

[0075] Preferably, at least one permanent magnet is made from a rare earth material. Suitable rare earth materials include, but are not limited to neodymium (Nd), dysprosium (Dy), and samarium (Sm). As an alternative preference, at least one permanent magnet is made from alnico alloy.

[0076] Preferably, at least one of the plurality of rotor magnets is hollow.

[0077] Preferably, at least one of the plurality of stator magnets is hollow. Preferably, at least one hollow rotor magnet or stator magnet is filled with magnetically inert material. The magnetically inert material can be, but is not limited to, compressed chalk or fired clay.

[0078] Preferably, each axle is made from a non-metallic material. In a preferred embodiment, each axle is made from a ceramic material. In an alternative preferred embodiment, each axle is made from a plastic material.

[0079] Preferably, each stator ring is made from a non-metallic material. In a preferred embodiment, each stator ring is made from fired ceramic clay. Preferably, each stator ring is made from fired ceramic clay using a lost wax method.

[0080] Preferably, each rotor assembly is made from a non-metallic material. In a preferred embodiment, each rotor assembly is made from fired ceramic clay. Preferably, each rotor assembly is made from fired ceramic clay using a lost wax method.

[0081] Preferably, the motor includes a brake. In one embodiment, the brake includes a block of copper that is positionable such that in accordance with Lenz’s Law the magnetic field of at least one of the plurality of rotors is opposed.

[0082] In an embodiment wherein each rotor assembly includes a plurality of planar rotors, each planar rotor is made from a non-metallic material. In a preferred embodiment, each planar rotor is made from fired ceramic clay. Preferably, each planar rotor is made from fired ceramic clay using a lost wax method.

[0083] In one embodiment the motor can have two or more sets of stator assemblies and corresponding rotor assemblies with the sets arranged adjacent one another. Preferably, the two or more sets of stator assemblies and corresponding rotor assemblies are operably connected. More preferably, the two or more sets of stator assemblies and corresponding rotor assemblies are operably connected to produce an output at a specific point.

[0084] In another aspect the present invention resides in a motor, including a stator assembly including a plurality of stator rings, the stator assembly defining a cavity; and a plurality of rotor assemblies, each rotor assembly including a plurality of rotors arranged on an axle, the axle having a longitudinal axis, each rotor assembly rotatable about the longitudinal axis of the respective axle, wherein each stator ring has a plurality of stator magnets; wherein each rotor has a plurality of rotor magnets; wherein each of the plurality of rotors is located within the cavity; wherein each of the plurality of rotors is operably associated with one of the plurality the stator rings; and wherein each of the plurality of rotors is coplanar with the corresponding operably associated stator ring.

[0085] In a further aspect the present invention resides in a rotor assembly, including a rotor arranged on an axle, the axle having a longitudinal axis, each rotor assembly rotatable about the longitudinal axis of the respective axle, wherein each rotor has a plurality of rotor layers; and wherein each rotor layer has a plurality of rotor magnets.

[0086] In a preferred embedment, the rotor of the rotor assembly is comprised of a plurality of rotors corresponding to each rotor layer. Preferably, each rotor layer is a separate planar rotor.

[0087] Preferably, the plurality of rotors are arranged in series, with each rotor being adjacent to at least one other rotor.

[0088] Preferably, each rotor is rotationally offset around the longitudinal axis from an adjacent rotor of the same rotor assembly. Preferably, each rotor is rotationally offset around the longitudinal axis from an adjacent rotor of the same rotor assembly by substantially 1 degree to 40 degrees. More preferably, each rotor is rotationally offset around the longitudinal axis from an adjacent rotor of the same rotor assembly by substantially 3 degrees to 10 degrees. Preferably, each rotor is rotationally offset around the longitudinal axis from an adjacent rotor of the same rotor assembly such that the plurality of lobes of one rotor is rotationally offset to the plurality of lobes of another rotor.

[0089] Preferably, a first rotor of at least one of the plurality of rotor assemblies has a first orientation and each adjacent rotor in series is rotationally offset from the preceding rotor around the longitudinal axis. Preferably, each rotor which is rotational offset along the rotor assembly is offset in the same rotational direction as each other offset rotor.

[0090] Preferably, with respect to at least one of the plurality of rotor assemblies wherein the rotor assembly has a first rotor, each the nthrotor in series from the first rotor is rotationally offset around the longitudinal axis from the first rotor by n*x, wherein x is a predetermined amount. Preferably, each of the plurality of rotor magnets has a proximal end closest to the axle of the corresponding rotor and a distal end furthest from the axle of the corresponding rotor.

[0091] Preferably, each of the plurality of rotor magnets has an operative end. Preferably, the distal end is the operative end of the rotor magnet.

[0092] Preferably, the distal end of one or more of the plurality of rotor magnets is shaped to produce a magnetic force of a desired shape. In one embodiment, the distal end of one or more of the plurality of rotor magnets has a convex shape. In another embodiment, the distal end of one or more of the plurality of rotor magnets has a flat shape.

[0093] Preferably, the rotor assembly produces a helical magnetic field.

[0094] Preferably, at least one of the plurality of rotor magnets is shaped to concentrate magnetic force in a specific area. In one embodiment, one or more of the plurality of rotor magnets have external ribs to concentrate magnetic force in a specific area.

[0095] Preferably, each rotor has a uniform shape.

[0096] Preferably, each of the plurality of rotors has a polygonal shape. More preferably, each of the plurality of rotors has a polygonal shape.

[0097] Preferably, the plurality of rotor magnets is arrayed such that at least one rotor magnet is positioned at each vertex of the polygonal shape of each rotor.

[0098] Preferably, the number of rotor magnets at each vertex of the polygonal shape of each rotor is the same. In one embodiment, the plurality of rotor magnets is arrayed such that rotor magnets are positioned at each vertex of the polygonal shape of each rotor. Preferably, each of the two rotor magnets are arranged such that one rotor magnet leads the other in a direction of rotation of the rotor. Preferably, each first of the two rotor magnets in a leading direction is more powerful than the second of the two rotor magnets.

[0099] Preferably, a rotor of one of the plurality of rotor assemblies is configured to intermesh with a rotor of another rotor assembly. Preferably, intermeshing rotors do not contact one another.

[0100] Preferably, each rotor assembly has a toothed gear on each respective axle. Preferably, the toothed gear on one rotor assembly intermeshes with a toothed gear on an adjacent rotor assembly. Preferably, the intermeshing toothed gears are configured to allow the corresponding rotor assemblies to rotate without contacting one another.

[0101] Preferably, each rotor magnet is elongate. Preferably, each rotor magnet has a longitudinal axis. In one embodiment, each of the plurality of rotor magnets are arranged radially within the rotor. Preferably, each rotor magnet is oriented such that the longitudinal axis of each rotor magnet is coincident with the longitudinal axis of the axle of the rotor assembly.

[0102] Preferably, at least one of the plurality of rotor magnets is a permanent magnet. Preferably, at least one of the plurality of rotor magnets is an electromagnet.

[0103] Preferably, at least one electromagnet is weaker than at least one permanent magnet.

[0104] Preferably, each permanent magnet is arranged to always be in a repulsion configuration.

[0105] Preferably, each electromagnet has an attraction configuration and a repulsion configuration.

[0106] Preferably, at least one permanent magnet is made from a rare earth material. Suitable rare earth materials include, but are not limited to neodymium (Nd), dysprosium (Dy), and samarium (Sm). As an alternative preference, at least one permanent magnet is made from alnico alloy.

[0107] Preferably, at least one of the plurality of rotor magnets is hollow.

[0108] Preferably, at least one hollow rotor magnet is filled with magnetically inert material. The magnetically inert material can be, but is not limited to, compressed chalk or fired clay.

[0109] Preferably, each axle is made from a non-metallic material. In a preferred embodiment, each axle is made from a ceramic material. In an alternative preferred embodiment, each axle is made from a plastic material.

[0110] Preferably, each rotor is made from a non-metallic material. In a preferred embodiment, each rotor is made from fired ceramic clay. Preferably, each rotor is made from fired ceramic clay using a lost wax method.

[0111] The features described with respect to one aspect also apply where applicable to all other aspects of the invention. Furthermore, different combinations of described features are herein described and claimed even when not expressly stated.

[0112] BRIEF DESCRIPTION OF THE DRAWINGS In order that the present invention can be more readily understood reference will now be made to the accompanying drawings which illustrate a preferred embodiment of the invention and wherein:

[0113] Figure 1 is a perspective view of a motor according to an embodiment of the present invention;

[0114] Figure 2 is a front view of the motor of Figure 1 ;

[0115] Figure 3 is a perspective cross-section view of the motor of Figure 1 showing cross-section A-A;

[0116] Figure 4 is a side cross-section view of the motor of Figure 1 showing crosssection A-A;

[0117] Figure 5 is a front cross-section view of the motor of Figure 1 showing crosssection B-B;

[0118] Figure 6 is a perspective cross-section view of the motor of Figure 1 showing cross-section C-C;

[0119] Figure 7 is a top cross-section view of the motor of Figure 1 showing crosssection C-C;

[0120] Figure 8 is a perspective view of the rotor assemblies of the motor of Figure 1 ;

[0121] Figure 9 is a top view of the rotor assemblies of the motor of Figure 1 ;

[0122] Figure 10 is a cross-section top view of a motor according to another embodiment of the present invention;

[0123] Figure 11 is a perspective view of a motor according to an embodiment of the present invention; and

[0124] Figure 12 is a perspective view of a motor according to an embodiment of the present invention.

[0125] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0126] With reference to Figures 1 to 9 there is shown a motor 10, including a stator assembly 20, a first rotor assembly 30, a second rotor assembly 40, a first end plate 50, and a second end plate 60.

[0127] The stator assembly 20 comprises a plurality of stator rings. The stator rings have a first configuration 22A and a second configuration 22B. The plurality of stator rings are arranged in series, with each stator ring 22A being adjacent to at least stator ring 22B. The stator assembly defines a cavity wherein each of the plurality of stator rings 22A.22B has an inner wall which defines a portion of the cavity.

[0128] The first end plate 50, the second end plate 60 and the stator assembly 22 including cavity thereof form a housing with an enclosed chamber 12.

[0129] The first rotor assembly 30 includes a plurality of rotors 32A to 32G arranged on an axle (not shown). The axle has a longitudinal axis 36. The first rotor assembly 30 is rotatable about the longitudinal axis 36.

[0130] The first rotor 32A has a first orientation and each adjacent rotor in series 32B,32C,... ,32G is rotationally offset from the preceding rotor around the longitudinal axis 36 by approximately 60 degrees.

[0131] The second rotor assembly 40 is a mirrored version of the first rotor assembly 30. The second rotor assembly 40 includes a plurality of rotors 42A to 42G arranged on an axle (not shown). The axle has a longitudinal axis 46. The first rotor assembly 40 is rotatable about the longitudinal axis 46.

[0132] Each rotor 32A to 32G and 42A to 42G is located within the cavity.

[0133] Each of the stator rings 22A.22B is operably associated with only one rotor per rotor assembly 30,40. Each of the plurality of rotors is coplanar with the corresponding operably associated stator ring 30,40.

[0134] The first rotor assembly 30 is configured to rotate in a first direction and the second rotor assembly 40 is configured to rotate in a second direction opposite the first direction.

[0135] The rotors 32A to 32G of the first rotor assembly 30 and the rotors 42A to 42G of the second rotor assembly 40 are configured to intermesh without touching each other.

[0136] The first rotor assembly 30 has a toothed gear 38 connected to the respective axle. The second rotor assembly 40 has a toothed gear 48 connected to the respective axle. The toothed gear 38 and the toothed gear 48 are configured to intermesh to allow the first rotor assembly 30 and second rotor assembly 40 to rotate without the rotors 32A to 32G and 42A to 42G contacting each other. In Figures 3 to 5 the gear 38 and the gear 48 are not shown for clarity.

[0137] Each stator ring 20A,20B has a plurality of elongate stator magnets 24.

[0138] Each of the of the plurality of stator magnets 24 has a proximal end closest to the cavity and a distal end furthest from the cavity. Each of the of the plurality of stator magnets 24 has an operative end. The proximal end of each stator magnet 24 is the operative end. Each stator magnet 24 is oriented such that the proximal end leads the distal end in the direction of rotation of the adjacent rotor assembly 30 / 40.

[0139] The plurality of stator magnets 24 are arrayed such that the operative end of each stator magnet 24 is at or adjacent the inner wall of the respective stator ring 22A.22B.

[0140] Each rotor 32A to 32G has a substantially identical, lobed shape. Each rotor 42A to 42G has a substantially identical, lobed shape.

[0141] Each rotor 32A to 32G and 42A to 42G has five pairs of rotor magnets 34,44. Each pair of rotor magnets 34,44 is positioned at one vertex of the polygonal shape of each rotor

[0142] Each stator ring 20A.20B has a different number of stator magnets 24 to number of rotor magnets 34,44 of each associated rotor.

[0143] The stator rings in the first configuration 22A have thirty-one stator magnets 24 with sixteen being arranged in a semi-circle about the first rotor assembly 30 and fifteen being arranged in a semi-circle about the second rotor assembly 40.

[0144] The stator rings in the second configuration 22B have twenty-nine stator magnets 24 with fifteen being arranged about the first rotor assembly 30 and fourteen being about the second rotor assembly 40.

[0145] Each of the of the pairs of rotor magnets 34,44 are arranged such that one rotor magnet 34,44 leads the other in a direction of rotation of the rotor assembly 30.

[0146] The plurality of rotors 32A to 32G are arranged in series, with each rotor 32A to 32G being adjacent to at least one other planar rotor 32A to 32G. The plurality of rotors 42A to 42G are arranged in series, with each rotor 42A to 42G being adjacent to at least one other planar rotor 42A to 42G.

[0147] Each first of each pair rotor magnets 34,44 in a leading direction is more powerful than the second of the pair of rotor magnets 34,44.

[0148] Each of the plurality of rotor magnets 34,44 is elongate and has a proximal end closest to the axle of the corresponding rotor and a distal end furthest from the axle of the corresponding rotor. The distal end is the operative end of the rotor magnet 34,44.

[0149] The plurality of rotor magnets 34,44 and the plurality of stator magnets 24 are arranged such that each rotor is out of phase with each associated stator ring.

[0150] Each rotor magnet 34,44 has a longitudinal axis. Each of the plurality of rotor magnets 34,44 are arranged radially within each rotor such that the longitudinal axis of each rotor magnet 34,44 is coincident with the longitudinal axis of the axle of the corresponding rotor assembly.

[0151] Each stator magnet 24 has a longitudinal axis and each stator magnet 24 is oriented such that the longitudinal axis of each stator magnet 24 is not coincident with the longitudinal axis of the axle of the adjacent rotor assembly.

[0152] Each rotor magnet 34,44 and approximately half of the plurality of stator magnets 24 are permanent magnets. The remaining stator magnets 24 are electromagnets which can be operated in an attraction configuration or a repulsion configuration. Each permanent magnet is arranged to always be in a repulsion configuration.

[0153] In use, each rotor magnet 34,44 produces a rotor magnetic field, and each stator magnet 24 produces a stator magnetic field. During operation the rotor magnetic field lags the stator magnetic field by 1 degree to 5 degrees and thus produces torque which is transmitted through the axle 38,48 of each rotor assembly 30,40.

[0154] Due to the arrangement of the stator assembly 20 and the rotor assemblies 30,40 the number and alignment of the plurality of rotor magnets 34,44 and the plurality of stator magnets 24 is such that at least one set of rotor magnet 34,44 and stator magnet 24 are in maximum repulsion at any time.

[0155] When the rotor magnet 34,44 and the stator magnet 24 are at their closest point the angle between the longitudinal axis of the rotor magnet 34,44 and the longitudinal axis of the stator is approximately 60 degrees.

[0156] With reference to Figure 10 there is shown a motor 100 comprising a first device 110 and a second device 120. Both the first device 110 and the second device 120 include a stator assembly, a first rotor assembly, a second rotor assembly, a first end plate, and a second end plate. The first device 110 and the second device 120 are attached together. The first device 110 and the second device 120 are operably connected to provide power via a single output (not shown).

[0157] With reference to Figure 11 there is shown an external view of a motor 200 which has three rotor assemblies (not shown). The rotor assemblies are operatively connected to each other by gears 210,212,214,216.

[0158] With reference to Figure 12 there is shown an external view of a motor 300 which has a single rotor assembly (not shown). ADVANTAGES

[0159] An advantage of the preferred embodiment of the motor includes that the arrangement of the rotor assemblies and the stator assembly and the corresponding rotor magnets and stator magnets ensure that during operation the time between when a first set of rotor magnet and stator magnet are in maximum repulsion and when a second set of rotor magnet and stator magnet are in maximum repulsion is minimal.. Another advantage of the preferred embodiment of the motor includes that the motor efficiently uses the momentum of the rotor assembly so that another set of rotor magnet and stator magnet are in maximum repulsion. As the different in rotation between the positions where a set of rotor magnet and stator magnet are in maximum repulsion and the subsequent set of rotor magnet and stator magnet are in maximum repulsion is minimized the window for losing momentum is also minimized and the transition between these positions is therefore more efficient.. A further advantage of the preferred embodiment of the motor includes that it reduces the required locked rotor torque to start the motor from a state where the rotor assemblies are stationary. Another advantage of a preferred embodiment of the motor includes that the complementary toothed gears of each axle of the plurality of rotor assemblies allow the rotor assemblies to rotate without contacting one another and thus reduces wear on the rotor assemblies..

[0160] VARIATIONS

[0161] While the foregoing has been given by way of illustrative example of this invention, all such and other modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of this invention as is herein set forth.

[0162] Throughout the description and claims of this specification the word “comprise" and variations of that word such as “comprises” and “comprising”, are not intended to exclude other additives, components, integers or steps.

Claims

CLAIMS1. A motor, including a stator assembly including a plurality of stator rings, the stator assembly defining a cavity; and at least one rotor assembly, each rotor assembly including a rotor arranged on an axle, each axle having a longitudinal axis, each rotor assembly rotatable about the longitudinal axis of the respective axle, wherein each stator ring has a plurality of stator magnets; wherein each rotor has a plurality of rotor magnets; wherein each rotor is located within the cavity; and wherein each rotor is operably associated with one of the plurality the stator rings.

2. A motor as claimed in claim 1 , wherein the at least one rotor assembly is a plurality of rotor assemblies.

3. A motor according to claim 1 or claim 2, wherein each rotor has a plurality of rotor layers, and wherein the plurality of rotor magnets are arranged on each rotor layer.

4. A motor according to claim 3, wherein each rotor layer is preferably rotationally offset around the longitudinal axis from an adjacent rotor layer of the same rotor assembly.

5. A motor according to any one of the preceding claims, wherein each of the of the plurality of stator magnets has a proximal end closest to the cavity and a distal end furthest from the cavity.

6. A motor according to claim 5, wherein each of the of the plurality of stator magnets has an operative end, the operative end being the proximal end of each stator magnet, and each stator magnet is oriented such that the proximal end leads the distal end in the direction of rotation of the adjacent rotor assembly.

7. A motor according to any one of the preceding claims, wherein the number and alignment of the plurality of rotor magnets and the plurality of stator magnets is such that at least one set of rotor magnet and stator magnet are in maximum repulsion at any time.

8. A motor according to any one of the preceding claims, wherein the number of rotor magnets of a rotor layer and the number of stator magnets of a stator ring associated with the rotor layer are preferably not the same.

9. A motor according to any one of the preceding claims, wherein each of the plurality of stator rings preferably has a prime number of stator magnets.

10. A motor according to any one of claims 3 to 9, wherein the motor includes two rotor assemblies and the plurality of stator magnets are arrayed so that n stator magnets are arranged about a first rotor layer and n-1 stator magnets are arranged about a second rotor layer.

11. A motor according to any one of claims 3 to 10, wherein the motor includes two rotor assemblies and the plurality of stator magnets are arrayed in a semi-circle arrangement about each rotor assembly.

12. A motor according to any one of claims 3 to 11 , wherein the number of rotor magnets in a rotor layer does not share a denominator with the number of stator magnets arranged about the rotor layer.

13. A motor according to any one of claims 3 to 12, wherein each rotor layer preferably has a different number of rotor magnets to number of stator magnets of the associated stator ring.

14. A motor according to any one of claims 3 to 13, wherein each stator ring preferably has a different number of stator magnets to number of rotor magnets of each associated rotor layer.

15. A motor according to any one of the preceding claims, wherein each rotor magnet has a longitudinal axis, each stator magnet has a longitudinal axis, and each stator magnet is oriented such that the longitudinal axis of each stator magnet is not coincident with the longitudinal axis of the axle of the adjacent rotor assembly.

16. A motor according to any one of claim 15, wherein when the rotor magnet and the stator magnet are at their closest point the angle between the longitudinal axis of the rotor magnet and the longitudinal axis of the stator is approximately 60 degrees.

17. A motor according to any one of the preceding claims, wherein the maximum distance between a rotor magnet and a stator magnet when the rotor magnet and the stator magnet are at their closest point is less than 1 mm.

18. A motor according to any one of the preceding claims, wherein the motor includes a brake.

19. A motor according to any one of claim 18, wherein the brake includes a block of copper that is positionable such that the magnetic field of at least one of the plurality of rotors is opposed.

20. A motor according to any one of the preceding claims, wherein at least one of the plurality of rotor magnets is a permanent magnet.

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