PCB Stator Thermal Layout for Axial Field Rotary Machines
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Solution Overview
Problem
Axial field electric machines with printed circuit board (PCB) stators face inefficiencies due to non-uniform flux distribution, leading to asymmetrical voltage induction and increased temperature rise from resistive and eddy current losses, which can result in premature failure of the PCB stator.
Innovation Solution
The implementation of a PCB stator assembly with thermally conductive layers and heat removal features, including external and internal thermally conductive layers, vias, and heat sinks, along with non-linear coil configurations to reduce eddy currents and enhance heat dissipation, balances voltage induction and lowers the overall temperature rise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If PCB stator structures are used in axial field electric machines, then device complexity is reduced and manufacturing is simplified, but temperature rise increases due to resistive and eddy current losses
Solution Approach 1:
The PCB stator is divided into multiple segments or sections, each with optimized coil configurations. This segmentation allows for better heat distribution and reduced concentration of eddy currents in single areas, thereby lowering overall temperature rise while maintaining manufacturing simplicity
Solution Approach 2:
Thermally conductive materials and heat dissipation structures are introduced as intermediary elements between the PCB stator and the surrounding environment. These intermediaries facilitate heat transfer from the PCB stator, reducing temperature rise without complicating the overall device structure
2Ease of manufacture
If conventional PCB stator designs are used, then ease of manufacture is improved, but reliability decreases due to premature failure from increased temperature
Solution Approach 1:
Heat dissipation features and thermal management structures are pre-integrated into the PCB stator design during manufacturing. This preliminary action prevents temperature-related failures before they occur, maintaining ease of manufacture while improving reliability through proactive thermal management
Solution Approach 2:
The PCB stator design incorporates modified electrical parameters such as optimized trace widths, copper weights, and coil configurations that reduce resistive losses. These parameter changes lower operating temperature and improve reliability without requiring complex manufacturing processes
3Manufacturing precision
If standard coil configurations are used in PCB stators, then manufacturing precision requirements are reduced, but energy losses increase due to non-uniform flux distribution and asymmetrical voltage induction
Solution Approach 1:
The coil configurations in the PCB stator are deliberately designed with asymmetric patterns that compensate for non-uniform flux distribution. This asymmetric design creates more uniform voltage induction across phases, reducing eddy current losses while maintaining relaxed manufacturing precision requirements
Solution Approach 2:
Curved or arc-shaped coil traces are implemented in the PCB stator instead of straight lines. These curved configurations better follow the magnetic flux lines, improving flux distribution uniformity and reducing energy losses without significantly increasing manufacturing complexity
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 solution improves the uniformity of voltage induction across phases and reduces temperature-related failures by effectively managing heat dissipation and minimizing eddy current losses, thereby enhancing the efficiency and reliability of the axial field rotary energy device.
Implementation Method 1
The stator assembly can have a thermally conductive layer that extends from an inner diameter portion to an outer diameter portion of the stator assembly
Implementation Method 2
The implementation of a PCB stator assembly with thermally conductive layers and heat removal features, including external and internal thermally conductive layers, vias, and heat sinks
Implementation Method 3
The implementation of a PCB stator assembly with thermally conductive layers and heat removal features, including external and internal thermally conductive layers, vias, and heat sinks
Implementation Method 4
non-linear coil configurations to reduce eddy currents and enhance heat dissipation
Data Source
AI summary
An axial field rotary energy device has a PCB stator panel assembly between rotors with an axis of rotation. Each rotor has a magnet. The PCB stator panel assembly includes PCB panels. Each PCB panel can have layers, and each layer can have conductive coils. The PCB stator panel assembly can have a thermally conductive layer that extends from an inner diameter portion to an outer diameter portion thereof.