Axial Flux PCB Stator Winding Layout Without Via-Trace Intersections
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Solution Overview
Problem
The manufacturing process of printed circuit board (PCB) stators for axial field rotary energy devices is complex and costly due to repetitive operations, and existing designs often require splitting PCB stators into panels that intersect vias with traces, leading to inefficiencies and potential eddy current losses.
Innovation Solution
The design incorporates PCB panels with conductive layers coupled to plated vias extending through the stator, where each major surface is covered with a dielectric material, and the number of coil turns is optimized to be a multiple of the number of phases, allowing for reduced manufacturing steps and preventing via intersections with traces, thus simplifying the manufacturing process and reducing eddy current losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If PCB stator is split into panels and processed individually through etching, laminating, drilling and plating operations, then manufacturing flexibility is improved, but manufacturing complexity and cost increase due to repetitive operations
Solution Approach 1:
The patent merges multiple PCB panels into a single monolithic PCB stator structure, eliminating the need for separate processing of individual panels. The single stator core includes multiple stator poles formed on one PCB, allowing all conductive layers and vias to be created in one integrated manufacturing process rather than repetitive operations on separate panels.
Solution Approach 2:
The single monolithic PCB stator serves multiple functions simultaneously - it provides the magnetic circuit core, contains all stator windings through conductive layers, and integrates all electrical connections through vias. This multi-functional design eliminates the need for separate processing steps that would be required if the stator were divided into multiple panels.
2Ease of manufacture
If via intersects with trace in PCB stator panel, then manufacturing is simplified, but eddy current losses increase reducing efficiency
Solution Approach 1:
The patent applies different via configurations to different locations within the PCB stator. In regions where eddy currents would be problematic, the design avoids via-trace intersections or uses specific via patterns that minimize eddy current paths. The via arrangement is optimized locally at each stator pole to prevent harmful eddy currents while maintaining manufacturing feasibility.
3Adaptability or versatility
If number of coil turns is not optimized relative to number of phases, then design flexibility is maintained, but efficiency decreases due to eddy current circulation
Solution Approach 1:
The patent optimizes the number of coil turns as a specific parameter to be a multiple of the number of phases (e.g., 3 turns per coil for a 3-phase device). This parameter optimization prevents the formation of closed eddy current loops in the PCB stator while maintaining the ability to configure different winding patterns and phase arrangements for various application requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a faster, more economical manufacturing process and improved efficiency by eliminating unnecessary steps and preventing eddy current circulation, enhancing the overall performance of axial field rotary energy devices.
Implementation Method 1
selected ones of the conductive layers are coupled to plated vias that extend from one major surface of the PCB stator to an opposite major surface of the PCB stator
Implementation Method 2
each major surface of the PCB stator can have a layer of a dielectric material that completely covers ends of the plated vias
Data Source
AI summary
An axial field rotary energy device are disclosed. For example, the device can include a printed circuit board (PCB) stator having PCB panels. Each PCB panel can include conductive layers. Selected ones of the conductive layers are coupled to plated vias that extend from one major surface of the PCB stator to an opposite major surface of the PCB stator. In addition, each major surface of the PCB stator can have a layer of a dielectric material that completely covers ends of the plated vias.