Segmented PCB Stator Architecture for Compact Axial Field Rotaries

The patent replaces traditional mechanical wire winding and interconnection systems with a printed circuit board (PCB) based system. The PCB stator uses standardized PCB manufacturing processes to create coil windings and electrical interconnections, eliminating the need for manual wire winding, insulation wrapping, and mechanical fastening operations. This substitution dramatically simplifies manufacturing while reducing device volume through more efficient space utilization of the PCB structure.

The patent divides the PCB stator into multiple modular segments, each containing a specific number of coils and electrical phases. These segments can be independently manufactured, tested, and assembled, reducing the overall complexity of any single PCB unit. The segmentation allows for standardized production of identical modules that can be replicated and combined to create different device configurations, thereby simplifying the manufacturing process while managing design complexity through modularity.

The patent separates the stator into multiple segments, each handling a specific electrical phase or coil set. This segmentation allows each segment to be manufactured as a simpler, more cost-effective PCB unit using standardized manufacturing processes. The segments are then assembled together to form the complete multi-phase stator, achieving the desired compactness while avoiding the exponential cost and complexity increases that would result from integrating all phases into a single complex PCB.