HK1091956B - Axial field rotary energy device - Google Patents

Description

Axial field rotary energy device

This application claims priority to provisional application No.60/445,884, filed on 7/2/2003.

Technical Field

The present invention relates to an optimized axial field rotational energy device that can be used as an engine to convert electrical energy into motion or as a generator to convert rotational energy into electrical energy. The present invention includes a stator formed by stacking a plurality of printed circuit boards in which a plurality of electronic components are arranged to achieve maximum power and efficiency.

Background

Axial air gap brushless motors with layered disc-shaped stators are known, such as US patent US 5789841 to Wang. The stator windings in Wang use metal wires interconnected in a wavy or coiled configuration. These engines are of large size and difficult to manufacture.

In addition, axial field electronics using printed circuit board stators are also known, such as shown in U.S. patent US 6411002 to Smith et al.

The present invention provides a rotary energy device operated with multi-phase electrical energy. The device is substantially flat and thin and provides an engine that can be used in conjunction with many tools and equipment currently in use, such as electric drills, power saws, lawn mowers, electric bicycles, washing machines and dryers. The device to which the invention relates is designed to minimize resistance and to minimize eddy and loop currents. The electromagnetic inductance is increased by minimizing the gap between the rotor magnet and the stator circuit, and also the manufacturing cost is substantially minimized since the motor is constructed with a printed circuit board.

Disclosure of Invention

The present invention provides an axial magnetic field rotary energy device having a multiphase current terminal of positive polarity and negative polarity, comprising: a rotor having a plurality of permanent magnetic poles thereon; and a stator having: a plurality of circuit board working conductor layers having at least one working conductor layer for each phase of current, each of the working conductor layers including a pattern of a plurality of radial conductors continuous between an inner diameter via located at an inner diameter of the working conductor layer and an outer diameter via located at an outer diameter of the working conductor layer; each working conductor layer further having a pair of outer conductors for electrically connecting positive and negative terminals of one phase of electrical current with the selected outer diameter vias and a plurality of inner conductors for electrically connecting the selected inner diameter vias together; a plurality of circuit boards of a connecting conductor layer, at least one circuit board being associated with each working conductor layer, and the connecting conductor layer of each circuit board including a pattern of a plurality of radial conductors continuing between an inner diameter via located at an inner diameter of the connecting conductor layer and an outer diameter via located at an outer diameter of the connecting conductor layer; each connecting conductor layer further having a plurality of outer conductors for electrically connecting together selected outer diameter vias and a plurality of inner conductors for electrically connecting together selected inner diameter vias; and a plurality of via conductors in selected ones of the inner and outer vias of the working conductor layer and the connecting conductor layer for electrically connecting selected ones of the radial conductors of the connecting conductor layer with selected ones of the radial conductors of the working conductor layer.

Drawings

In order that the invention may be more clearly understood and readily carried into effect, preferred embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 is a partially exploded view of a stator used in the manner of the present invention, with some parts broken away;

FIG. 2 is a view of the stator shown in FIG. 1 with some parts broken away;

FIG. 3 is a view of the stator shown in FIG. 2 with some parts broken away;

FIG. 4 is an exploded view of an energy device in accordance with the present invention;

FIG. 5 is a cross-sectional view of an energy device in accordance with the present invention;

FIG. 6 is a plan view of a first working conductor layer used in conjunction with the stator shown in FIG. 1;

fig. 6A is a plan view of the first working conductor layer shown in fig. 6 with some details of the conductor pattern removed;

fig. 7 is a plan view of a first connecting conductor layer used in conjunction with the stator shown in fig. 1;

fig. 8 is a plan view of a second working conductor layer for use in the stator shown in fig. 1;

fig. 9 is a plan view of a second connecting conductor layer used in the stator shown in fig. 1;

fig. 10 is a plan view of a third working conductor layer for use in the stator shown in fig. 1;

fig. 11 is a plan view of a third connecting conductor layer used in the stator shown in fig. 1;

fig. 12 is a plan view of a separate conductor layer used in the stator according to the present invention;

FIG. 13A is an exploded cross-sectional view illustrating a method of formation in the stator layer;

FIG. 13B is a cross-sectional view showing the stacked stator layers shown in FIG. 13A;

FIG. 13C is the same cross-sectional view as shown in FIG. 13B with plated through holes;

fig. 14 is a detail view of a radial conductor used in conjunction with a conductor layer according to a first embodiment of the present invention;

fig. 15 is a detail view showing a radial conductor of six conductor layers connected in parallel according to the present invention;

fig. 16 is a plan view of the first working conductor layer shown in fig. 6;

fig. 17 is a plan view of the first connecting conductor layer shown in fig. 7 with auxiliary lighting (highlighting);

fig. 18 is a plan view of a conductor layer according to a second embodiment of the present invention;

fig. 19 is a detail view of a radial conductor used in conjunction with a conductor layer according to a third embodiment of the present invention;

fig. 20 is a detail view of a radial conductor used in conjunction with a conductor layer according to a fourth embodiment of the present invention;

fig. 21 is a detail view of a radial conductor used in conjunction with a conductor layer according to a fifth embodiment of the present invention;

fig. 22 is a detail view of a radial conductor used in conjunction with a conductor layer according to a sixth embodiment of the present invention;

fig. 23 is a detail view of a radial conductor used in conjunction with a conductor layer according to a seventh embodiment of the present invention;

fig. 24 is a detail view of a radial conductor used in conjunction with a conductor layer according to an eighth embodiment of the present invention; and

fig. 25 is a partially exploded view of the stator shown in fig. 1 with the split conductor layers shown in fig. 12.

Detailed Description

The present invention includes a stator formed by stacking a plurality of Printed Circuit Boards (PCBs) containing a plurality of circuits made of conductive material and supported by a non-conductive dielectric material. In general, the present invention is flat, thin, and has a circular, square, or other shape suitable for the function of the device.

By way of non-limiting example, FIG. 1 shows a three-dimensional view of a preferred embodiment of the present invention comprising six PCB layers arranged in a three-phase current configuration. The three phases are denoted herein as A, B and C. In fig. 1, the axial scale has been exaggerated for clarity, and the non-conductive material has been removed as electrical insulation and mechanical support. Fig. 1 shows one of many possible arrangements by which the phase a, phase B and phase C circuits interfit and bypass each other. In fig. 2, the phase C circuit has been removed so that some parts can be more easily seen. Fig. 2 shows one of many possible arrangements by which the phase a circuit cooperates with the phase B circuit and bypasses each other. As is clear from fig. 3, where both the phase B and phase C circuits have been removed, the phase a circuit includes a layer of conductive material. Each layer of conductive material is made up of a plurality of radial conductors, represented by radial conductor 2, and a plurality of non-radial conductors, represented by non-radial conductors 3, 4 and 5. The radial and non-radial conductors are connected together in series on the same conductor layer and are also connected in series with the conductors on the other conductor layer by a plurality of interlayer conductors, represented by interlayer conductor 6. The interlayer conductors may also connect corresponding radial conductors on different layers of conductive material in parallel. A phase a circuit having a plurality of radial and non-radial conductors connected together in series or in series and parallel on the same layer and interconnected in series and parallel or in series or in parallel between layers is interfitted with and bypasses any other phase circuits contained in the same layer of conductive material. Phase circuits A, B and C are shown in fig. 1-3 as being formed from six layers of conductive material, but other embodiments of the invention may have fewer or greater numbers of layers of conductive material.

As shown in fig. 1-3, and as described below, the size, spatial arrangement, and interconnection of each of the conductors in the phase A, B and C-circuit are optimized based on the function and desired performance of the device incorporating the present invention. The size, spatial arrangement, and interconnection of one conductor on one layer of conductive material may vary independently of any other conductor on the same layer of conductive material. The size, spatial arrangement, and interconnection of one conductor on one layer of conductive material may vary independently of the size, spatial arrangement, and interconnection of any other conductor on any other layer of conductive material. As an example, fig. 3 shows such a radial conductor 2, said radial conductor 2 having a width smaller than the width of the non-radial conductor 3, although they are interconnected on the same layer of conductive material. By selectively manipulating the size, spatial arrangement, and interconnection of each of the conductors in the phase A, B and C-circuit, the device may be optimized for a number of factors, including (but not limited to) resistance, electromagnetic inductance, eddy and loop current generation, heat dissipation, and manufacturing costs. Preferred embodiments of the present invention will be described in detail below in order to further explain the scope of the novel invention.

A preferred embodiment of the present invention is shown in fig. 4. A conductor optimized energy apparatus 10 configured to function as a motor or a generator comprising: two housings 11 and 12, a drive shaft 13, a shaft key 13a, two rotors 14a and 14b, a conductor optimized stator 15, two bearings 16a and 16b, two axially magnetized permanent magnets 17a and 17b, a wave washer 18, and three hall sensors 19. Device 10 also includes stator phase connector 20, stator sensor connector 21, electronic control board 22, control phase connector 23, control sensor connector 24, control heat sink 25, and control cover 26. The electronic control board 22 provides electronic sensing and control means to facilitate proper delivery of current to the conductor optimized stator 15. Electronic control board 22 is connected to a dc power source, such as a battery pack or a dc power source (not shown). Electronic control board 22 is also referred to in the art as a motor drive and uses conventional types of components that currently exist, such as integrated circuit chips, power transistors, regulators, diodes, transistors, and capacitors.

Stator phase connector 20 is connected to control phase connector 23 and stator sensor connector 21 is connected to control sensor connector 24 to connect electronic control board 22 to conductor optimized stator 15. Also shown are bolts 27 and nuts 28 for fastening together the housing 11, the housing 12 and the control cover 26. The control mounting bolts 29 fasten the electronic control board 22 and the control heat sink 25 to the housing 11.

Still referring to fig. 4, the magnets 17a and 17b are axially magnetized and have poles N and S alternating around the ring. Magnets 17a and 17b are shown and described as ring magnets, but may be made as separate parts. Magnets 17a and 17b preferably comprise at least one rare earth metal, such as an alloy of neodymium, iron, and boron. When assembled in the device 10 as shown in fig. 5, the magnets 17a and 17b are attached to the rotors 14a and 14 b. With the magnets 17a and 17b arranged such that the N pole on the magnet 17a faces the N pole on the magnet 17b, the rotors 14a and 14b are fixedly secured to the drive shaft 13 on opposite sides of the stator 15. The magnets 17a and 17b generate magnetic flux between them perpendicular to the surface of the conductor optimized stator 15. Magnets 17a and 17b are shown and described as having four poles, however, device 10 may be constructed with magnets having other numbers of poles, such as two, six, eight, sixteen or any other even number of poles that may be manufactured.

In fig. 5, the housings 11 and 12, which are made of a rigid material such as molded plastic or an alloy containing aluminum or magnesium, support the bearings 16a and 16 b. The drive shaft 13 is supported by the two bearings 16a and 16b and the drive shaft 13 protrudes through an opening in the housing 12. Rotors 14a and 14b connected with magnets 17a and 17b are attached to the shaft 13. The rotors 14a and 14b are made of a magnetically permeable material, such as steel, to provide flux return for the magnets 17a and 17 b. The magnets 17a and 17b generate a concentrated magnetic flux therebetween. The housings 11 and 12 hold the conductor optimized stator 15 in position between the rotors 14a and 14b and across the air gaps 31a and 31b from the magnets 17a and 17 b. The portion of conductor optimized stator 15 that is located in the concentrated magnetic flux between magnets 17a and 17b defines working conductor portion 30. When the proper collection and delivery allows the device 10 to behave as a generator or alternator, the rotation of the external means of the magnets 17a and 17b will induce a current in the conductive material of the working conductor portion 30. In contrast, a suitable application of current into the conductive material of the working conductor portion 30 will generate a lorentz force between the flowing current and the magnetic field. The force generated is a torque that rotates the magnets 17a and 17b, which are firmly connected to the rotors 14a and 14b, wherein the rotors 14a and 14b are firmly connected to the drive shaft 13. The drive shaft 13 may be used to do work and the device 10 may thus behave as a motor or an actuator.

The novel features of the conductor optimized energy device 10 will be described in connection with a preferred embodiment of the present invention. Conductor optimized stator 15 of device 10 includes stacked PCB layers of conductive material supported by multiple layers of nonconductive material. Fig. 6-11 each show a conductor pattern for a layer of conductive material in the conductor optimized stator 15. Fig. 6 shows the conductive material of an operating conductor layer in conductor optimized stator 15 having an "operating" PCB pattern 32. Each layer of conductive material is supported by a layer of conductive material that separates it from other layers of conductive material. Each layer of conductive material in conductor optimized stator 15 may have the same or different PCB pattern 32. The pattern of each layer represents an electrical conductor composed of an electrically conductive material, such as copper, and electrically insulated and mechanically supported by a non-conductive material, such as fiberglass. The conductor pattern for each layer may be created by various methods including, but not limited to, etching, stamping, spraying, cutting, or machining. A preferred method is to chemically etch conductor patterns, such as conductor pattern 32, into a plurality of two-sided circuit boards 39 made of a sheet of fiberglass sandwiched between two copper sheets. By way of non-limiting example, fig. 13A-13C schematically illustrate how the conductor optimized stator 15 is manufactured. In fig. 13A, three two-sided circuit boards 39 are stacked together with two fiberglass sheets 40 between them. In fig. 13B, stacked circuit boards 39 and fiberglass sheets 40 are laminated together by heat and pressure to form a multi-board arrangement for conductor optimized stator 15. A central hole 41 is formed to allow the shaft 13 to pass therethrough. As shown in fig. 13C, a plurality of holes 42 are drilled and the holes 42 may be plated with a conductive material, such as copper, to form a plurality of plated holes, as represented by plated holes 43 in fig. 13C.

It is preferable to use a circuit board having a copper plate thicker than that used in the most commonly manufactured circuit board. Copper plate thicknesses in the range of 0.004 inch to 0.007 inch are preferred, but copper plates of other thicknesses may be used. As previously shown in fig. 1, a copper plate thickness in the preferred range produces a ribbon-like conductor when viewed without supporting glass fibers. Referring again to fig. 6, holes are drilled in precise locations through the multiple circuit boards of the conductor optimized stator 15, after which the inner walls of the holes are plated with a conductive material (such as copper). Plated holes, also referred to as vias (vias), provide a plurality of interlayer conductors, represented by vias 201 and 301 that electrically connect conductors on different layers of conductor optimized stator 15. Although plated holes are shown and described in this embodiment, it should be understood that other interlayer conductor means are possible, including (but not limited to) holes filled with conductive material, metal pins, crimp points, spot welds, or wires. As previously described, the various conductors on different layers of conductor optimized stator 15 connected together in series and parallel by vias comprise the optimized conductor circuit of the present invention. Present day circuit board manufacturing techniques can provide small differences in conductor size, spatial arrangement, stator thickness for conductor optimized stator 15 quality, as well as one hundred percent assurance of conductor circuit continuity.

In the presently described preferred embodiment shown in fig. 4-11, there are three optimized conductor circuits in the conductor optimized stator 15, one for each power phase of the three phase power circuit. As previously described, fig. 6 shows the conductive material of an operating conductor layer in the conductor optimized stator 15 formed by the operating PCB pattern 32. Fig. 7 shows the conductive material of a connecting conductor layer in conductor optimized stator 15, which is made up of a "connecting" PCB pattern 33. PCB pattern 32 of fig. 6 and PCB pattern 33 of fig. 7 are formed of conductors connected together to electrically complete a portion of the phase a circuit. PCB patterns 32 and 33 also include conductors associated with the phase B and C circuits. Similarly, the working PCB pattern 34 shown in fig. 8 and the connecting PCB pattern 33 shown in fig. 9 are formed of conductors connected together to electrically complete a portion of the phase B circuit. PCB patterns 34 and 35 also include conductors associated with the phase a and C circuits. Also, the working PCB pattern 36 shown in fig. 10 and the connection PCB pattern 37 shown in fig. 11 are made up of conductors connected together to facilitate power completion of a portion of the phase C circuit. PCB patterns 36 and 37 also include conductors associated with the phase a and B circuits.

The pattern of radial conductors in the PCB patterns 32, 33, 34, 35, 36 and 37 is the same in all working conductor layers and connecting conductor layers.

Fig. 12 shows a PCB layer of conductive material having a PCB pattern 38 of radial conductors identical to the pattern of radial conductors in the other PCB layers. PCB pattern 38 also includes a plurality of connectors 44 for connecting a plurality of sensor terminals 45 to a plurality of sensor mounting pads 46. Sensor mounting pads 46 provide for surface mounting of a device (such as an array of hall sensors) for detecting the poles N and S of magnets 17a and 17 b. One hall sensor 19 is shown mounted to one sensor mounting pad 46. Sensor mounting pad 46A provides for surface mounting for a temperature sensing device, such as a thermistor. The sensor terminals 45 provide a connection means for an external electronic control device, such as a motor driver. PCB pattern 38 also includes conductors associated with phase A, B and the C circuit. Fig. 25 shows PCB pattern 38 on top of stacked PCB patterns 32, 33, 34, 35, 36 and 37 shown previously in fig. 1. PCB pattern 38 is preferably a top or bottom layer to facilitate surface mounting of sensors and connectors, such as connection of hall sensor 19 to sensor mounting pads 46, connection of stator phase connectors 20 to phase terminals 53, and connection of stator sensor connector 21 to sensor terminals 45. Radial conductor I PCB pattern 38 is electrically connected to phase circuits A, B and C of PCB patterns 32, 33, 34, 35, 36 and 37 by via conductors.

Referring now to fig. 6A, PCB pattern 32 is made up of a number of concentric ring-shaped portions that differ in the function of the conductors they contain. Fig. 6A shows various functional ring-like portions of PCB pattern 32 with certain parts of PCB pattern 32 removed for clarity. The following description of the functional ring portions of PCB pattern 32 should be applicable to each PCB pattern on each layer of conductive material of conductor optimized stator 15. Also shown in fig. 6A is magnet 17b having poles N and S. The magnet 17b is arranged behind the conductor optimized stator 15 shown in fig. 6A, while the magnet 17a (not shown) is in the same position, but above the conductor optimized stator 15. The PCB pattern 32 has a working conductor portion 30 defined by poles N and S of the magnet 17 a. In other words, the working conductor portion 30 is the portion of the conductor optimized stator 15 traversed by the magnetic flux between the magnets 17a and 17 b. As shown in fig. 6A, there are multiple phase sections of the working conductor section 30 denoted A, B and C. The total number of phase sections is equal to the number of poles multiplied by the number of electrical phases used. In the presently described embodiment, the device 10 uses a three-phase configuration and four poles, so the working conductor section 30 has a total of 12 phase sections. The device 10 may also be configured for use with other multiphase configurations that vary the number of phase sections. By way of non-limiting example, another embodiment of the device 10 using a five-phase configuration and four poles would have the working conductor portion 30 divided into 20 phase portions. As shown in fig. 6A, the arrangement of phase portions A, B and C is continuous around working conductor portion 30, and the combined area of the three phase portions is equal to the area of one pole.

Still referring to fig. 6A, other portions of the PCB pattern 32 will be described. Radially inward of the working conductor portion 30 is an inner through hole portion 47. Radially inward of the inner via portion is an inner non-radial conductor portion 48. Radially inward of the inner non-radial conductor portion 48 is a shaft hole 49. Radially inward of the working conductor portion 30 is an outer via portion 50. Radially outward of the outer via portion 50 is an outer non-radial conductor portion 51. Radially outward of the outer non-radial conductor portion 51 is a heat sink portion 52. Heat sink portion 52 is in contact with housings 11 and 12 to provide a means for transferring heat from conductor optimized stator 15 to housings 11 and 12. One area of the heat sink portion 52 is denoted as a terminal portion 53, which terminal portion 53 provides a connection means to an external power system, such as a motor driver, a rectifier or a converter.

The PCB pattern 32 of the conductor optimized stator 15 is shown to have six concentric ring-shaped portions, but other embodiments of the invention with a lower or higher number of concentric ring-shaped portions are possible.

The terminal part 53 includes terminals 53A, 53B, 53C, 53D, 53E and 53F, two terminals being used for each phase of the power supply circuit. As shown in fig. 1, each stacked layer has these terminals connected together by a through-hole connector. The working conductor layer 32 is connected to the terminals 53A, 53B. The working conductor layer 34 is connected to the terminals 53C, 53D. The working conductor layer 36 is connected to the terminals 53E, 53F.

As shown in fig. 6-11, the size and shape of the first conductor in the first portion of PCB pattern 32 is generally different than the size and shape of the second conductor in the second portion of PCB pattern 32. In addition, the size, shape, and location of the conductors in the first portion of the first pattern on the first layer of the conductor optimized stator 15 may be the same or different than the conductors in the corresponding first portion of the second pattern of the second layer of the conductor optimized stator 15. This is in contrast to conductors in conventional motors and generators that are wound with a fixed diameter wire, which means that the conductor has a constant size and shape throughout the motor or generator.

The structural shape of the conductive material in each section of PCB pattern 32 depends on what functional role each section performs for conductor optimized stator 15. As previously shown and described, phase portions A, B and C are in the flux field between magnets 17a and 17 b. Referring now to fig. 14, a portion of PCB pattern 32 is shown having a portion of working conductor portion 30, an inner via portion 47, an inner non-radial conductor portion 48, a shaft hole 49, an outer via portion 50, and an outer non-radial conductor portion 51. As an example of how the conductors are optimized in different parts of the PCB pattern 32, the radial conductors 101 and some related non-radial conductors will be described in detail. In the presently described embodiment, radial conductor 101 includes a working conductor 101a having a width 54, where width 54 is constant in working conductor portion 30 and width 54 is symmetrical along radius 55. Radial conductor 101 also includes an inner pad 101b having a width 56 in inner via portion 47 and an outer pad 101c having a width 57 in outer via portion 50. Width 54 is less than or equal to width 56. Width 54 is less than width 57. Since the width 54 lies in a plane perpendicular to the magnetic flux, an increased width 54 will result in an increase in eddy currents in the working conductor 101 a. When the device 10 is used as a generator or motor, the eddy currents generate a force opposing the rotation of the magnets 17a and 17b, robbing the device 10 of electricity. The speed of rotation of magnets 17a and 17b is one factor used to determine width 54. Faster rotational speeds generate more eddy currents, and thus embodiments of the device 10 configured to rotate at high speeds will have a smaller value of the width 54 than the value of the width 54 in embodiments of the device 10 configured to rotate at low speeds. Resistance is another factor used to determine the value of width 54. When the device 10 is used as a generator or motor, the resistance robs the device 10 of power. The electrical resistance generates heat as current flows through the conductive material of the conductor optimized stator 15 and increases as the temperature of the conductive material increases. The resistance increases as the width 54 decreases. Therefore, to reduce losses due to resistance, a maximum value for width 54 may be selected. However, depending on the operating speed of the device 10, a maximum value of the width 54 may result in substantial losses due to eddy currents. Therefore, the value of the width 54 of the working conductor 101a is selected to balance the eddy current loss and the resistance loss.

Referring to fig. 6 and 14, the pad 101b is in the inner via portion 47. Inner vias 201 electrically connect inner pads 101b of radial conductors 101 with corresponding radial conductors on other layers of conductive material in conductor optimized stator 15. Inner pad 101b is connected to inner non-radial conductor 58 having width 59. Width 59 of inner non-radial conductor 58 is preferably greater than or equal to width 56 of inner pad 101b of radial conductor 101. The outer pad 101c has outer vias 301 that connect the pad 101c of the radial conductor 101 with corresponding radial conductors on other layers of conductive material in the conductor optimized stator 15. Outer pad 101c is connected to outer non-radial conductor 62 having width 61. Width 61 is preferably greater than or equal to width 57. In fig. 14, inner pad 101b is shown connected to inner non-radial conductor 63 and outer pad 101c is shown connected to outer non-radial conductor 62. However, in the presently described embodiment, inner pad 101b of radial conductor 101 is connected only to inner non-radial conductor 63 in PCB pattern 32 shown in fig. 6 and inner non-radial conductor 65 in PCB pattern 33 shown in fig. 7. The outer pad 101c is connected only to the outer non-radial conductor 62 in the PCB pattern 32 shown in fig. 6. The radial conductors 101 in the PCB patterns 34, 35, 36 and 37 shown in fig. 8, 9, 10 and 11, respectively, are not shown as being connected to either the inner non-radial conductor or the outer non-radial conductor. It should be appreciated that radial conductors 101 may be selectively connected to inner non-radial conductors 63 or outer non-radial conductors 62 on any layer of conductive material in conductor optimized stator 15.

Referring again to fig. 14, inner pad 101b and outer pad 101c of radial conductor 101, inner non-radial conductor 63, and outer non-radial conductor 62 are not subjected to the concentrated magnetic field of magnets 17a and 17 b. Thus, eddy currents are not a factor, and widths 56, 57, 59, and 61 are made as large as possible in the respective portions of its conductor optimized stator 15 in order to reduce the resistance of the total current. Another way to reduce the overall resistance of the conductor circuit in the conductor optimized stator 15 is to connect corresponding conductors on different layers of conductive material in parallel. As a non-limiting example, fig. 15 shows six layers of radial conductors 101 electrically connected in parallel by vias 201 and 301. The total resistance of the plurality of parallel conductors (each having a resistance value) is equal to the total number divided by the reciprocal of each resistance value. When the conductors each have the same resistance value (such as each of the six layers of radial conductors 101 shown in fig. 15), the formula can be simplified to a total resistance equal to the resistance value of one conductor divided by the number of parallel conductors. For example, if the radial conductor 101 of the first layer has a resistance value of 0.006ohms, and the radial conductors 101 in each of the other five layers have the same resistance value, then the total resistance value of the six layers of radial conductors 101 is equal to 0.006ohms divided by six conductors, or 0.001 ohms. Fig. 15 shows a parallel connection of a set of radial conductors on six layers. Fig. 3 shows the parallel connection of the radial conductors of each part of the phase a circuit on six layers.

As an example of how the conductor optimized stator 15 functions, the path of the current when it flows through one circuit of the present embodiment when the device 10 is determined to be functioning as a motor will be described. Referring now to fig. 16, the working conductor region 30 of the working PCB pattern 32 is made up of radial conductors 101 to 172. In the presently illustrated preferred embodiment, each phase section contains six radial conductors carrying current through the phase section in the same direction. Radial conductors 101 to 106 are in a positive phase sector a, radial conductors 107 to 112 are in a positive phase sector B, and working conductors 113 to 118 are in a positive phase sector C. Radial conductors 119 to 124 are in negative phase sector a, radial conductors 125 to 130 are in negative phase sector B, and radial conductors 131 to 136 are in negative phase sector C. Radial conductors 137 to 142 are in timing phase portion a, radial conductors 143 to 148 are in timing phase portion B, and radial conductors 149 to 154 are in timing phase portion C. Radial conductors 155 through 160 are in negative phase sector a, radial conductors 161 through 166 are in negative phase sector B, and radial conductors 167 through 172 are in negative phase sector C. It should be noted that other embodiments having a lesser or greater number in each phase section may be manufactured depending on the desired output requirements of the apparatus 10.

The radial conductors of each phase section are connected in series to provide a plurality of currents through the working area 30. Fig. 16 shows the previously described working PCB pattern 32 with the protruding phase a circuitry, while fig. 17 shows the connecting conductor PCB pattern 33 also with the protruding phase a circuitry.

In fig. 16, current is delivered from the control device to the a + terminal 53B. A control device, such as the electronic control board 22 described previously, uses the sensing devices to determine the polarization of the magnetic flux generated by the permanent magnets 17a and 17b passing through each phase portion of the phase circuits A, B and C. The sensing means is preferably an array of hall sensors mounted on the conductor optimized stator 15. The control device uses a plurality of power transistors or MOSFETS that switch current to phase circuits A, B and C at appropriate times and periods to facilitate generating and maintaining rotation of the device based on the input of the hall sensor array. The control device is located outside the device 10 and the electrical connection between the control device and the conductor optimized stator 15 may be performed by a separate conductor, such as a bundle of wires or a ribbon cable.

Current moves from the a + terminal 53B through the outer non-radial conductor 62. The current is introduced into radial conductor 101 and passes through radial conductor 101 before entering inner non-radial conductor 63. The inner non-radial conductor 63 directs current into and through the radial conductor 124. From which point the current leaves the working PCB pattern 32. The current passes through the outer via 324 to the connecting PCB pattern 33 in fig. 17. From outer via 324, current passes through outer non-radial conductor 64 to radial conductor 102. The current passes through radial conductor 102 to inner non-radial conductor 65, into radial conductor 123, then to outer non-radial conductor 66 and into radial conductor 103. Each time current passes through the radial conductor, the current passes through the working conductor region 30. The current is connected to the current passing through radial conductors 122, 104, 121, 105, 120, 106 and 119. The current returns from radial conductor 119 through via 319 to the working PCB pattern 32 shown in fig. 16. From via 319, the current passes through outer non-radial conductor 67 and into radial conductor 137. From radial conductor 137, the current passes through inner non-radial conductor 68 to radial conductor 160. Current must pass through outer vias 360 to connect PCB pattern 33, again referring to fig. 17, where current can flow through outer non-radial conductor 69 to radial conductor 138. Current flows from radial conductor 138 into inner non-radial conductor 70 and then into radial conductor 159. The current is connected to the current passing through radial conductors 139, 158, 140, 157, 141, 156, 142, and 155. From radial conductor 155, current is introduced to working PCB pattern 32 shown in fig. 16 through outer vias 355. From the outer via 355, the current passes through the outer non-radial conductor 71 to the A-terminal 53A. Current is delivered from the a-terminal 53A back to the control. In the same manner, the working pattern 34 is connected with the terminals 53C and 53D and the current flows through the phase B circuit included in the working PCB pattern 34 and the connection PCB pattern 35, as shown in fig. 8 and 9. In addition, the working pattern 36 is connected to the terminals 53E and 53F and current flows through the phase C circuit included in the working PCB pattern 36 and the connection PCB pattern 37, as shown in fig. 10 and 11. As previously shown and illustrated in fig. 15, the outer vias 301 and inner vias 201 connect the radial conductors 101 contained on each layer of conductive material in the PCB patterns 32, 33, 34, 35, 36, 37 in a parallel fashion. Similarly, radial conductors 102 through 172 shown in fig. 16 and 17 are connected in parallel to a corresponding radial conductor for each layer of conductive material in conductor optimized stator 15 by outer vias 302 through 372 and by inner vias 202 through 272.

Another embodiment of the present invention is shown in fig. 18. The embodiment includes a PCB pattern 91 for use in conjunction with the stator 15. Differences from the previous embodiments include means for positioning magnetic pole sensors (such as hall sensors 95 in the working area 30. pattern 91 includes sensor pockets 92. sensor pockets 92 are empty areas through all conductive and non-conductive measurement layers. sensor pockets 92 are sized and arranged to allow magnetic pole sensors to be placed in the concentrated magnetic flux between magnets 17a and 17 b. radial conductors proximate to sensor pockets 92 are constructed to provide adequate clearance and maintain connections in the conductor optimized stator 15.

In addition to the above, the present invention provides other embodiments for optimizing the conductors of the conductor optimized stator 15. As previously mentioned, fig. 15 shows a structure of a radial conductor 101, said radial conductor 101 comprising one straight working conductor 101a symmetrical about the radius 55, and an inner via pad 101b, an inner via 201, an outer via pad 101c and an outer via 301. By way of non-limiting example, fig. 19 to 24 show other possible means for optimising the conductor of the invention. Fig. 19 shows a radial conductor 101 as described above, comprising three vias 201 in the inner pad 101b and three vias 301 in the outer pad 101 c. Increasing the number of vias connecting radial conductors 101 to radial conductors 101 on each layer of conductive material increases the total plated area of each connection, which reduces the resistance of the circuit. Although three through holes 201 and three through holes 301 are shown, it should be understood that other numbers of through holes are possible.

Another embodiment shown in fig. 20 shows a radial conductor 401, which radial conductor 401 is composed of two working conductors 401a and 401 b. Working conductors 401a and 401b are parallel to radius 55 and have equal width 402. Radial conductor 401 is shown with two working conductors. However, other numbers of working conductors may be used. The width of each individual working conductor is minimized to help reduce eddy current losses. Having multiple working conductors (such as working conductors 401a and 401b) in parallel reduces the electrical resistance and improves the outward transfer of heat when compared to a single working conductor.

Fig. 21 shows another possible embodiment of a radial conductor within the scope of the invention. The branch conductor 501 is shown as the working conductor 501a connected to the inner pad 501 b. Working conductor 501a branches radially outward into working conductors 501d and 501e, and branches into working conductors 501f, 501g, and 501 h. Branching conductor 501 is another method for reducing eddy current losses, reducing electrical resistance, and increasing the transfer of heat to the outer edge of conductor optimized stator 15.

In fig. 22 and 23, a plurality of vias 602 in the working area 30 pass through a pair of working conductors from one side of the radius 55 to the other. In fig. 22, radial conductor 601 is composed of working conductors 601a, 601b, 601c, and 601 d. Working conductors 601a and 601b are connected as shown and working conductors 601c and 601d terminate at via 602 as shown. The current passing through working conductor 601a is on one side of the radius and then passes to the other side of the radius in working conductor 601 b. The current flowing in 601c is connected to the further layer of conductive material via a via 602 which is formed as shown in fig. 23. The current moves from via 602 into working conductor 601c and then through radius 55 into working conductor 601 d. On the layer of conductive material shown in fig. 23, working conductors 601a and 601b terminate at vias 602. The current passing through working conductor 601a is connected to the layer of conductive material shown in fig. 22, where it moves through radius 55 into working conductor 601d after being connected to working conductor 601 a. Passing through the working conductor in the manner just described is a method of reducing the loop current induced in the parallel conductors in an alternating magnetic field.

Fig. 24 shows another embodiment with a radial conductor 701, said radial conductor 701 consisting of a midpoint 702, said midpoint 702 being a distance 703 from the radius 55 and a distance 704 from the center 705 of the conductor optimized stator 15. The midpoint 702 may have the same or different values for the distance 703 and the distance 704 on different layers of conductive material in the conductor optimized stator 15. Bending the radial conductor away from radius 55 in the manner just described is a way to reduce cogging.

The different configurations of the radial conductors shown in fig. 14 and 15 and in fig. 19-24 are presented as non-limiting examples, and it should be understood that many other configurations are possible that can further optimize the conductors.

While there have been shown and described fundamental novel features of the invention, it will be understood that various substitutions, modifications and changes may be made by those skilled in the art without departing from the spirit or scope of the invention. Accordingly, all such modifications and changes are intended to be included within the scope of this invention as defined in the following claims.

Claims (12)

1. An axial magnetic field rotary energy device having polyphase current terminals of positive and negative polarity, comprising:

a rotor having a plurality of permanent magnetic poles thereon; and

a stator having:

a plurality of circuit board working conductor layers having at least one working conductor layer for each phase of current, each of the working conductor layers including a pattern of a plurality of radial conductors continuous between an inner diameter via located at an inner diameter of the working conductor layer and an outer diameter via located at an outer diameter of the working conductor layer;

each working conductor layer further having a pair of outer conductors for electrically connecting positive and negative terminals of one phase of electrical current with the selected outer diameter vias and a plurality of inner conductors for electrically connecting the selected inner diameter vias together;

a plurality of circuit boards of a connecting conductor layer, at least one circuit board being associated with each working conductor layer, and the connecting conductor layer of each circuit board including a pattern of a plurality of radial conductors continuing between an inner diameter via located at an inner diameter of the connecting conductor layer and an outer diameter via located at an outer diameter of the connecting conductor layer;

each connecting conductor layer further having a plurality of outer conductors for electrically connecting together selected outer diameter vias and a plurality of inner conductors for electrically connecting together selected inner diameter vias; and

a plurality of via conductors in selected ones of the inner and outer vias of the working conductor layer and the connecting conductor layer for electrically connecting selected ones of the radial conductors of the connecting conductor layer with selected ones of the radial conductors of the working conductor layer.

2. The rotary energy device according to claim 1, wherein each of the circuit board working conductor layers has a planar configuration and each of the circuit board connecting conductor layers has a planar configuration, and the stator is formed by stacking the working conductor layers and the connecting conductor layers one above the other with a substrate layer between each of the working conductor layers.

3. The rotary energy device according to claim 2, wherein the stator has a central bore therethrough in a direction perpendicular to the planar configuration of the working conductor layer and the connecting conductor layer, and further comprising a rotatable drive shaft passing through the central bore, and further comprising a first rotor fixedly connected to the drive shaft on one side of the stator and a second rotor fixedly connected to the drive shaft on an opposite side of the stator.

4. The rotary energy device of claim 3, further comprising a sensing device mounted to the stator for determining a rotational position of the permanent magnet pole.

5. The rotary energy device according to claim 3, wherein the permanent magnetic poles of the first rotor are arranged relative to the permanent magnetic poles of the second rotor such that flux lines pass through the stator in a direction perpendicular to the planar structure of the working conductor layer.

6. The rotary energy device of claim 3, wherein each rotor has at least four permanent magnetic poles.

7. The rotary energy device according to claim 1, wherein the device is configured for use in an electrical circuit of at least three phases.

8. The rotary energy device according to claim 1, wherein the radial conductors of the working conductor layer and the connecting conductor layer have preselected widths, and the outer and inner conductors of the working conductor layer and the outer and inner conductors of the connecting conductor layer have widths greater than the preselected widths.

9. The rotary energy device of claim 1, wherein each working conductor layer and each connecting conductor layer is divided into a plurality of sections, wherein each section is associated with a positive or negative polarity of each phase current and a radial conductor passes through each said section.

10. The rotary energy device according to claim 9, wherein the inner conductor of each working conductor layer together with the inner and outer conductors of each connecting conductor layer connect the radial conductors in each said portion associated with a phase of the electrical current together in series through the via conductors.

11. The rotary energy device according to claim 10 wherein the device is configured for at least three-phase electrical circuits and the rotor comprises at least four permanent magnetic poles and each working conductor layer and each connecting conductor layer is divided into at least twelve sections and the working conductor layer comprises at least one outer conductor for connecting the section associated with the negative polarity of a phase with the section associated with the positive polarity of a phase.

12. The rotary energy device according to claim 10, wherein the radial conductors of each working conductor layer and each connecting conductor layer are arranged in the same pattern, and corresponding radial conductors in each working conductor layer and each connecting conductor layer are electrically connected in parallel by via conductors.