System and apparatus for axial field rotary energy device

Patent metadata

Field	Value
Publication number	US-RE50666-E
Application number	US-202318385744-A
Country	US
Kind code	E1
Filing date	Oct 31, 2023
Priority date	Jul 10, 2018
Publication date	Nov 18, 2025
Grant date	Nov 18, 2025

Abstract

An axial field rotary energy device can include a housing having an axis. A stator assembly is mounted to the housing and has stator panels that are axially-stacked and discrete panels from each other. Each stator panel includes a respective printed circuit board (PCB) having respective coils that are electrically conductive and interconnected within the respective PCB. In addition, a rotor assembly including rotors is rotatably mounted within the housing on opposite axial ends of the stator assembly. The rotors can be mechanically coupled together. Each rotor can include magnets having leading and trailing edges. The trailing edge of one magnet and the leading edge of an adjacent magnet can be parallel to each other to define a consistent circumferential spacing, relative to the axis, between adjacent ones of the magnets.

First claim

We claim:

1 . An axial field rotary energy device, comprising:
a housing having an axis with an axial direction; a stator assembly mounted to the housing and comprising a plurality of stator panels that are co-axial, each stator panel comprises a respective printed circuit board (PCB) having a respective plurality of coils that are electrically conductive and interconnected within the respective PCB, wherein each stator panel is configured to be connected to a single electrical phase; and a rotor assembly comprising rotors rotatably mounted within the housing, the rotors are mechanically coupled together, each motor rotor comprises magnets, the magnets comprise leading and trailing edges, and the trailing edge of each magnet and the leading edge of an adjacent magnet are parallel to each other to define a consistent circumferential spacing of the magnets, relative to axis; and wherein each respective PCB comprises PCB layers, each coil on a respective stator panel is formed by a single, concentric, electrically conductive trace on a single PCB layer of the respective PCB, the coils on each PCB layer are rotationally aligned, with respect to the axis, with the coils on other ones of the PCB layers, and each coil is coupled within the respective PCB to other coils on the same PCB layer and to coils on different PCB layers of the respective PCB.

2 . The device of claim 1 , wherein the stator assembly is configured to be connected to a plurality of electrical phases, and the stator panels are rotationally offset from each other, relative to the axis, at a desired angle.

3 . The device of claim 1 , wherein the rotors and stator panels are interleaved axially.

4 . The device of claim 3 , wherein the rotor assembly comprises four rotors interleaved axially with three stator panels.

5 . The device of claim 1 , wherein each stator panel comprises two identical, C-shaped PCB segment halves that are electrically coupled together to form a respective one of the stator panels.

6 . The device of claim 1 , wherein the stator panels are axially stacked and collectively mechanically coupled to the housing with fasteners in an axially-abutting relationship.

7 . The device of claim 1 , wherein each stator panel comprises a plurality of perimeter mounting holes that enable the plurality of stator panels to, relative to the axis, be rotationally offset from each other at desired phase angles as a multi-phase device.

8 . The device of claim 1 , wherein each rotor comprises a rotor hub, a magnetic backing is mounted to one axial side of the rotor hub, the magnets are mounted to an opposite axial side of the rotor hub, and the magnets are attached to the magnetic backing.

9 . The device of claim 8 , wherein collectively the magnets define a magnet inner diameter and a magnet outer diameter relative to the axis, the magnet backing has a backing inner diameter that is less than the magnet inner diameter, and the magnetic backing has a backing outer diameter that is greater than the magnet outer diameter.

10 . The device of claim 8 , wherein the rotor hub comprises a trapezoidal aperture for each of the magnets.

11 . The device of claim 1 , wherein the housing comprises housing shells that are coupled together, each of the housing shells respectively comprises an internal perimeter having a shelf formed therein, and the stator assembly is mechanically coupled to at least one of the shelves.

12 . The device of claim 1 , wherein each of the stator panels is configured to operate with a respective electrical phase, and the device is configured to operate with a source having a same number of electrical phases as the device.

13 . The device of claim 1 , wherein the rotors are mounted on opposite axial ends of the stator assembly.

14 . An axial field rotary energy device, comprising:
a housing having an axis with an axial direction, the housing comprises housing shells that are coupled together, and each of the housing shells respectively comprises an internal perimeter having a shelf formed therein; a stator assembly mounted to the housing and comprising a plurality of stator panels that are co-axial, each stator panel comprises a respective printed circuit board (PCB) having a respective plurality of coils that are electrically conductive and interconnected within the respective PCB, wherein each stator panel is configured to be connected to a single electrical phase; a rotor assembly comprising rotors rotatably mounted within the housing, the rotors are mechanically coupled together, each motor comprises magnets, the magnets comprise leading and trailing edges, and the trailing edge of each magnet and the leading edge of an adjacent magnet are parallel to each other to define a consistent circumferential spacing of the magnets, relative to axis; the stator assembly is mechanically coupled to at least one of the shelves; and wherein each respective PCB comprises PCB layers, each coil on a respective stator panel is formed by a single, concentric, electrically conductive trace on a single PCB layer of the respective PCB, the coils on each PCB layer are rotationally aligned, with respect to the axis, with the coils on other ones of the PCB layers, and each coil is coupled within the respective PCB to other coils on the same PCB layer and to coils on different PCB layers of the respective PCB.

15 . The device of claim 14 , wherein the stator assembly is configured to be connected to a plurality of electrical phases, and the stator panels are rotationally offset from each other, relative to the axis, at a desired angle.

16 . The device of claim 14 , wherein the stator panels are axially stacked and collectively mechanically coupled to the housing with fasteners in an axially-abutting relationship.

17 . The device of claim 14 , wherein each rotor comprises a rotor hub, a magnetic backing is mounted to one axial side of the rotor hub, the magnets are mounted to an opposite axial side of the rotor hub, and the magnets are attached to the magnetic backing.

18 . The device of claim 1 , wherein each of the stator panels is configured to operate with a respective electrical phase, and the device is configured to operate with a source having a same number of electrical phases as the device.

19. An axial field rotary energy device, comprising:
a housing having an axis with an axial direction; a rotor assembly having at least one rotor rotatably mounted in the housing; a stator assembly mounted to the housing and comprising a plurality of stator panels that are co-axial, each stator panel comprises a respective printed circuit board (PCB) having a respective plurality of coils that are electrically conductive and interconnected within the respective PCB, wherein each stator panel is configured to be connected to a single electrical phase, wherein each respective PCB comprises PCB layers, each coil on a respective stator panel is formed by a single, concentric, electrically conductive trace on a single PCB layer of the respective PCB, the coils on each PCB layer are rotationally aligned, with respect to the axis, with the coils on other ones of the PCB layers, and each coil is coupled within the respective PCB to other coils on the same PCB layer and to coils on different PCB layers of the respective PCB; and each stator panel has a plurality of magnetic cores that are electrically insulated from the PCB stator coils.

20. The axial field rotary device of claim 19 , wherein the magnetic cores are located at centers of respe

Assignees

• Infinitum Electric Inc

Inventors

• Schuler Bernhard L
• Lee Rich
• Rasmussen Jorgen

Classifications

• H02K2213/03

  Machines characterised by numerical values, ranges, mathematical expressions or similar information · 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

• H02K21/24 Primary

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

• H02K16/02 Primary

  Machines with one stator and two {or more} rotors · CPC title

• H02K16/00

  Machines with more than one rotor or stator {(machines for transmitting mechanical power from a driving shaft to a driven shaft and comprising structurally interrelated motor and generator parts H02K51/00; permanent magnet machines with multiple rotors or stators relatively rotated for vectorially combining the excitation fields or the armature voltages H02K21/029)} · CPC title