Printed circuit board electrical machine

Patent metadata

Field	Value
Publication number	US-11799342-B2
Application number	US-202117166746-A
Country	US
Kind code	B2
Filing date	Feb 3, 2021
Priority date	Feb 20, 2020
Publication date	Oct 24, 2023
Grant date	Oct 24, 2023

Abstract

An electric machine includes a plurality of permanent magnets and a plurality of conductors. The plurality of permanent magnets are arranged radially around a rotation axis of the electric machine and spaced apart from the rotation axis of the electric machine. At least one of the plurality of magnets has a shape in a plane of rotation intersected by the rotation axis. The plurality of conductors are arranged relative to the plurality of magnets and spaced apart from each other circumferentially around the rotation axis of the electric machine. At least one of the plurality of conductors includes a trace having a polygon shape different than the shape of the at least one of the plurality of magnets.

First claim

We claim:

1. An electric machine comprising:
a plurality of permanent magnets arranged radially around a rotation axis of the electric machine and spaced apart from the rotation axis of the electric machine, wherein at least one of the plurality of magnets has a shape in a plane of rotation intersected by the rotation axis;
a printed circuit board including a plurality of layers, each layer including a plurality of conductors arranged relative to the plurality of magnets and spaced apart from each other circumferentially around the rotation axis of the electric machine, at least one of the plurality of conductors including a trace having a polygon shape different than the shape of the at least one of the plurality of magnets; and
a top layer circumferential trace electrically connecting a conductor of the plurality of conductors on a top layer of the plurality of layers to a connector configured to provide current to an external load or receive current from an external source, and a bottom layer circumferential trace electrically connecting a conductor of the plurality of conductors on a bottom layer of a plurality of layers to the connector, such that current flowing from the top layer circumferential trace to the bottom layer circumferential trace flows through the conductor of the plurality of conductors on the top layer and the conductor of the plurality of conductors on the bottom layer to the bottom layer circumferential trace.

2. The electric machine of claim 1 , wherein the polygon shape comprises a first side at a first radial distance from the rotation axis of the electric machine, a second side at a second radial distance from the rotation axis of the electric machine, and at least one radial side extending between the first side and the second side.

3. The electric machine of claim 2 , wherein the first side comprises a first length different than a second length of the second side such that the at least one radial side is at an angle with a radius of the electric machine extending from the rotation axis.

4. The electric machine of claim 1 , further comprising:
a rotating assembly including the plurality of permanent magnets; and
a stationary assembly including the plurality of conductors in each layer of the plurality of layers.

5. The electric machine of claim 1 , further comprising:
a rotating assembly including the plurality of conductors in each layer of the plurality of layers; and
a stationary assembly including the plurality of permanent magnets.

6. The electric machine of claim 1 , wherein a quantity for the plurality of conductors in one layer of the plurality of layers is different than a quantity for the permanent magnets.

7. The electric machine of claim 6 , wherein the quantity for the plurality of conductors in one layer of the plurality of layers is greater than the quantity for the permanent magnets.

8. The electric machine of claim 1 , wherein the at least one of the plurality of conductors spiral inwardly to a first via in a first layer of a circuit board.

9. The electric machine of claim 8 , wherein the at least one of the plurality of conductors spiral outwardly to a second via in a second layer of the circuit board.

10. The electric machine of claim 9 , wherein the at least one of the plurality of conductors spiral inwardly to the first via in a clockwise direction and outwardly to the second via in the clockwise direction.

11. The electric machine of claim 9 , wherein the at least one of the plurality of conductors spiral inwardly to a third via in a third layer of the circuit board.

12. The electric machine of claim 1 , wherein the electric machine is an alternator.

13. The electric machine of claim 1 , wherein the electric machine is a motor.

14. A multiple layer printed circuit board for an electric machine, the printed circuit board comprising:
a plurality of layers, each layer including a plurality of conductors arranged relative to a plurality of magnets and spaced apart from each other circumferentially around a rotation axis of the electric machine, at least one of the plurality of conductors including a trace having a polygon shape different than the shape of at least one of the plurality of magnets; and
a top layer circumferential trace electrically connecting a conductor of the plurality of conductors on a top layer of the plurality of layers to a connector configured to provide current to an external load or receive current from an external source, and a bottom layer circumferential trace electrically connecting a conductor of the plurality of conductors on a bottom layer of the plurality of layers to the connector, such that current flowing from the top layer circumferential trace to the bottom layer circumferential trace flows through the conductor of the plurality of conductors on the top layer and the conductor of the plurality of conductors on the bottom layer to the bottom layer circumferential trace.

15. The electric machine of claim 14 , wherein the polygon shape comprises a first side at a first radial distance from the rotation axis of the electric machine, a second side at a second radial distance from the rotation axis of the electric machine, and at least one radial side extending between the first side and the second side.

Assignees

• Kohler Co

Inventors

• Frampton Isaac S
• Larson Adam

Classifications

• H02K3/26 Primary

  consisting of printed conductors · CPC title

• H02K1/2795

  the rotor consisting of two or more circumferentially positioned magnets · CPC title

• H02K15/0407

  Manufacturing of windings by etching, printing or stamping the complete coils · CPC title

• H02K21/24 Primary

  with magnets axially facing the armatures, e.g. hub-type cycle dynamos · CPC title

• H02K2203/03

  Machines characterised by the wiring boards, i.e. printed circuit boards or similar structures for connecting the winding terminations · CPC title