JP2023068153A - Axial-direction magnetic flux motor, flat-surface composite construction improved for dynamo-electric generator, and assembly - Google Patents

Abstract

A planar composite structure and assembly for axial flux motors and generators.
A planar composite structure (PCS) for use in an axial flux motor or generator is a conductive layer disposed on a dielectric layer that, when energized, comprises at least two counterparts of the motor or generator. A conductive layer may be included with conductive traces forming portions of at least two windings that generate magnetic flux for the phases. The PCS may additionally or alternatively comprise a first conductive trace forming a first portion of a winding that, when energized, produces a magnetic flux for a first phase of the motor or generator. Layers, at least one first conductive layer and a second conductive layer comprising second conductive traces forming a second portion of the winding. A first portion of the winding may be connected in series with a second portion of the winding such that the same amount of current is applied to each of the first and second portions of the winding. may be configured and arranged to flow through.
[Selection drawing] Fig. 10A

Description

(Related application)
This application is based on (A) U.S. patent application Ser. /530,552, filed July 10, 2017, entitled "STRUCTURES AND METHODS OF STACKING SUBASSEMBLIES IN PLANAR COMPOSITE STATORS TO OBTAIN HIGHER WORKING VOLTAGES". The contents of each of the above applications, publications, and patents are hereby incorporated by reference in their entirety for all purposes.

It is known to use planar composite structures (PCS) as stators in axial flux motors or generators. An example of such a stator is described in U.S. Pat. No. 7,109,625 (“the '625 patent”, US Pat.

U.S. Pat. No. 7,109,625

SUMMARY In some embodiments, a planar composite structure (PCS) for use in an axial flux motor or generator comprises a dielectric layer and a first conductive layer disposed on the dielectric layer. The first conductive layer is energized to generate a magnetic flux for a first phase of the motor or generator and a first portion of the first winding to generate a magnetic flux for a first phase of the motor or generator when energized. A first conductive trace forms a first portion of a second winding that produces magnetic flux for the second phase.

In some embodiments, a planar composite structure (PCS) for use in an axial flux motor or generator comprises a dielectric layer, a first conductive layer located on a first side of the dielectric layer; a second conductive layer located on a second side of the dielectric layer. The first conductive layer comprises first conductive traces that, when energized, form a first portion of the windings that produce magnetic flux for a first phase of the motor or generator. A second conductive layer has a second conductive trace forming a second portion of the winding. A first portion of the winding is connected in series with a second portion of the winding, the first and second portions of the winding having the same amount of current flowing through the first and second portions of the winding. configured and arranged to flow through each of the

In some embodiments, a planar composite structure (PCS) for use in an axial flux motor or generator comprises a first conductive layer comprising a first conductive trace and a second conductive trace. a second conductive layer comprising a third conductive trace; a third conductive layer comprising a third conductive trace; and a fourth conductive layer comprising a fourth conductive trace. The first conductive trace includes a first radial conductor extending radially from a first radial distance to a second radial distance that is greater than the first radial distance; The trace includes a second radial conductor extending radially from the first radial distance to a second radial distance, and a third conductive trace extends from the first radial distance to the second radial distance. a third radial conductor radially extending a radial distance; and a fourth conductive trace radially extending a fourth radial distance from the first radial distance to the second radial distance. Includes radial conductors. A first radial conductor is electrically connected to a corresponding one of the second radial conductors by a first blind or buried via, and a third radial conductor is electrically connected to a corresponding one of the second radial conductors by a second blind or buried via. are electrically connected to corresponding ones of the four radial conductors.

In some embodiments, a planar composite structure (PCS) for use in an axial flux motor or generator is radially spaced from a first radial distance to a second radial distance that is greater than the first radial distance. A subassembly having a first conductive layer including a first radial conductor extending in a direction, a first end turn conductor and a second end turn conductor. A first end-turn conductor interconnects a first group of first radial conductors to form a first winding for a first phase of an axial flux motor or generator. A second end-turn conductor interconnects a second group of the first radial conductors to form a second winding for a second phase of the axial flux motor or generator. The first subassembly includes more second end-turn conductors than first end-turn conductors.
The present invention provides, for example, the following.
(Item 1)
A planar composite structure (PCS) for use in an axial flux motor or generator, said PCS comprising:
a dielectric layer;
a first conductive layer disposed on the dielectric layer;
The first conductive layer comprises a first conductive trace, the first conductive trace comprising:
a first portion of a first winding which, when energized, produces a magnetic flux for a first phase of said motor or generator;
and a first portion of a second winding which, when energized, produces magnetic flux for a second phase of said motor or generator.
(Item 2)
The first conductive trace comprises:
First radial conductors, each of said first radial conductors extending radially between at least a first radial distance and a second radial distance greater than said first radial distance. a first radial conductor extending to
a first conductive end-turn;
The PCS of item 1, wherein each of said first conductive end-turns interconnects a respective pair of said first radial conductors.
(Item 3)
the first conductive end-turn comprises a first outer end-turn and a second outer end-turn;
said first outer end turn electrically interconnecting a first pair of portions of said first radial conductor at said second radial distance;
said second outer end turn electrically interconnecting a second pair of portions of said first radial conductor at said second radial distance;
said first portion of said first winding comprises said first outer end-turn;
3. The PCS of item 2, wherein the first portion of the second winding comprises the second outer end-turn.
(Item 4)
the first conductive end-turn comprises a first inner end-turn and a second inner end-turn;
said first inner end turn electrically interconnecting a first pair of portions of said first radial conductor at said first radial distance;
said second inner end turn electrically interconnecting a second pair of portions of said first radial conductor at said first radial distance;
the first portion of the first winding comprises the first inner end-turn;
3. The PCS of item 2, wherein the first portion of the second winding comprises the second inner end-turn.
(Item 5)
the first winding comprises a second portion electrically connected in series with the first portion of the first winding;
said first conductive end-turn further comprising a first outer end-turn;
The first outer end turn comprises a portion of one of the first pair of the first radial conductors at the second radial distance and a portion of the first pair of radial conductors at the second radial distance. electrically interconnecting a portion of another one of the radial conductors;
5. The PCS of item 4, wherein the second portion of the first winding comprises the first outer end-turn.
(Item 6)
Item 5, wherein said first inner end-turn and said first outer end-turn are arranged such that said first portion and second portion of said first winding form a serpentine pattern. PCS described in .
(Item 7)
the first conductive layer on a first side of the dielectric layer;
the PCS further comprising a second conductive layer located on a second side of the dielectric layer;
The second conductive layer comprises a second conductive trace forming a third portion of the first winding, the third portion of the first winding being equal to the first winding. 7. The PCS of item 5 or item 6 connected in series with said second portion of line.
(Item 8)
The second conductive trace comprises:
second radial conductors, each of said second radial conductors radially extending between at least said first radial distance and said second radial distance; a second radial conductor electrically connected to a corresponding one of the radial conductors;
a second conductive end-turn;
8. The PCS of item 7, wherein each of said second conductive end-turns interconnects a respective pair of said second radial conductors.
(Item 9)
the second conductive end-turn comprises a third inner end-turn;
said third inner end turn electrically interconnecting a first pair of portions of said second radial conductor at said first radial distance;
9. The PCS of item 8, wherein the third portion of the first winding comprises the third inner end-turn.
(Item 10)
the first winding comprises a fourth portion electrically connected in series with the third portion of the first winding;
said first conductive end-turn further comprising a second outer end-turn;
said second outer end turn electrically interconnecting a second pair of portions of said second radial conductor at said second radial distance;
10. The PCS of item 8 or item 9, wherein the fourth portion of the first winding comprises the second outer end-turn.
(Item 11)
the first winding comprises a fourth portion electrically connected in series with the third portion of the first winding;
said second conductive end-turn further comprising a second outer end-turn;
The second outer end turn is a portion of one of the first pair of the second radial conductors at the second radial distance and the second radius at the second radial distance. electrically interconnecting a portion of another one of the directional conductors;
10. The PCS of item 8 or item 9, wherein the fourth portion of the first winding comprises the second outer end-turn.
(Item 12)
Item 8, further comprising vias through said dielectric layer, said vias electrically interconnecting each of said second radial conductors with a corresponding one of said first radial conductors. - The PCS of any one of clauses 11.
(Item 13)
13. The PCS of any one of items 8-12, wherein the first winding comprises a first serpentine winding and the second winding comprises a second serpentine winding.
(Item 14)
A planar composite structure (PCS) for use in an axial flux motor or generator, said PCS comprising:
a dielectric layer;
A first conductive layer located on a first side of the dielectric layer, the first conductive layer conducting magnetic flux for a first phase of the motor or generator when energized. a first conductive layer comprising a first conductive trace forming a first portion of the resulting winding;
a second conductive layer located on a second side of said dielectric layer, said second conductive layer comprising a second conductive trace forming a second portion of said winding; a second conductive layer comprising
the first portion of the winding is connected in series with the second portion of the winding;
The PCS, wherein the first and second portions of the winding are constructed and arranged such that the same amount of current flows through each of the first and second portions of the winding.
(Item 15)
The first conductive trace comprises:
First radial conductors, each of said first radial conductors extending radially between at least a first radial distance and a second radial distance greater than said first radial distance. a first radial conductor extending to
a first conductive end-turn;
each of said first conductive end-turns interconnecting a respective pair of said first radial conductors;
The second conductive trace comprises:
second radial conductors, each of said second radial conductors radially extending between at least said first radial distance and said second radial distance; a second radial conductor electrically connected to a corresponding one of the radial conductors;
a second conductive end-turn;
15. The PCS of item 14, wherein each of said second conductive end-turns interconnects a respective pair of said second radial conductors.
(Item 16)
the first conductive end-turn comprises a first inner end-turn;
said first inner end turn electrically interconnecting a first pair of portions of said first radial conductor at said first radial distance;
the first portion of the winding comprises the first inner end-turn;
the second conductive end-turn comprises a second inner end-turn;
said second inner end turn electrically interconnecting a first pair of portions of said second radial conductor at said first radial distance;
16. The PCS of item 15, wherein the second portion of the winding comprises the second inner end-turn.
(Item 17)
the winding further comprises a third portion electrically connected in series between the first portion of the winding and the second portion of the winding;
said first conductive end-turn further comprising a first outer end-turn;
The first outer end turn comprises a portion of one of the first pair of the first radial conductors at the second radial distance and the first radius at the second radial distance. electrically interconnecting a portion of another one of the directional conductors;
17. The PCS of item 16, wherein the third portion of the winding comprises the first outer end-turn.
(Item 18)
The first inner end-turn, the second inner end-turn, and the first outer end-turn are configured such that the first, second, and third portions of the first winding form a serpentine pattern. 18. The PCS of item 17, arranged to.
(Item 19)
the winding comprises a fourth portion electrically connected in series with the second portion of the winding;
said first conductive end-turn further comprising a second outer end-turn;
said second outer end turn electrically interconnecting a second pair of portions of said second radial conductor at said second radial distance;
19. The PCS of item 17 or item 18, wherein the fourth portion of the winding comprises the second outer end-turn.
(Item 20)
the winding comprises a fourth portion electrically connected in series with the second portion of the winding;
said second conductive end-turn further comprising a second outer end-turn;
The second outer end turn is a portion of one of the first pair of the second radial conductors at the second radial distance and the second radius at the second radial distance. electrically interconnecting a portion of another one of the directional conductors;
19. The PCS of item 17 or item 18, wherein the fourth portion of the winding comprises the second outer end-turn.
(Item 21)
further comprising vias through said dielectric layer, said vias electrically interconnecting each of said second radial conductors with a corresponding one of said first radial conductors, items 15-20 PCS according to any one of.
(Item 22)
the first conductive layer is included in a first subassembly of the PCS;
the second conductive layer is included in a second subassembly of the PCS;
the first subassembly includes a third portion of the winding;
the third portion of the winding includes the first portion of the winding;
the third portion of the winding surrounds a first region of the first subassembly at least once;
the second subassembly includes a fourth portion of the winding;
the fourth portion of the winding includes the second portion of the winding;
17. The PCS of any one of items 14-16, wherein the fourth portion of the winding at least once surrounds a second region of the second subassembly.
(Item 23)
A planar composite structure (PCS) for use in an axial flux motor or generator, said PCS comprising:
A first conductive layer comprising a first conductive trace, said first conductive trace being from a first radial distance a second radial distance greater than said first radial distance a first conductive layer comprising a first radial conductor extending radially to
A second conductive layer comprising a second conductive trace, said second conductive trace radially extending from said first radial distance to said second radial distance. a second conductive layer including a second radial conductor;
A third conductive layer comprising a third conductive trace, said third conductive trace radially extending from said first radial distance to said second radial distance a third conductive layer including a third radial conductor;
A fourth conductive layer comprising a fourth conductive trace, said fourth conductive trace radially extending from said first radial distance to said second radial distance a fourth conductive layer comprising a fourth radial conductor;
said first radial conductors being electrically connected to corresponding ones of said second radial conductors by first blind or buried vias;
The PCS, wherein said third radial conductors are electrically connected to corresponding ones of said fourth radial conductors by second blind or buried vias.
(Item 24)
said first conductive trace further comprising first conductive end-turns, each said first conductive end-turn interconnecting a respective pair of said first radial conductors;
said second conductive trace further comprising a second conductive end-turn, each of said second conductive end-turns interconnecting a respective pair of said second radial conductors;
said third conductive trace further comprising a third conductive end-turn, each said third conductive end-turn interconnecting a respective pair of said third radial conductors;
said fourth conductive trace further comprising fourth conductive end-turns, each said fourth conductive end-turn interconnecting a respective pair of said fourth radial conductors; The PCS of item 23.
(Item 25)
The first radial conductor, the second radial conductor, the first conductive end-turn, and the second conductive end-turn are energized to form a first electrical conductor of the motor or generator. establishing an electrical path for a first portion of the winding that produces the magnetic flux for the phase;
The third radial conductor, the fourth radial conductor, the third conductive end-turn, and the fourth conductive end-turn provide an electrical path for a second portion of the winding. establish and
25. The PCS of item 24, wherein the first portion of the winding is connected in series with the second portion of the winding.
(Item 26)
A planar composite structure (PCS) for use in an axial flux motor or generator, said PCS comprising a first subassembly comprising a first conductive layer, said first conductive layer comprising , a first radial conductor extending radially from a first radial distance to a second radial distance greater than said first radial distance; a first end turn conductor; and a second end. turn conductors and
The first end turn conductor interconnects a first group of the first radial conductors to form a first winding for a first phase of the axial flux motor or generator. ,
The second end turn conductor interconnects a second group of the first radial conductors to form a second winding for a second phase of the axial flux motor or generator. ,
The PCS, wherein the first subassembly includes more second end-turn conductors than first end-turn conductors.
(Item 27)
Further comprising a second subassembly comprising a second conductive layer different from said first conductive layer, said second conductive layer comprising a second radial conductor and a third and a fourth end-turn conductor,
The third end turn conductor interconnects the first group of the second radial conductors to form a third winding for a first phase of the axial flux motor or generator. ,
The fourth end turn conductor interconnects a second group of the second radial conductors to form a fourth winding for a second phase of the axial flux motor or generator. ,
27. The PCS of item 26, wherein the first subassembly includes more third end-turn conductors than fourth end-turn conductors.
(Item 28)
28. The PCS of item 27, wherein the third winding is connected in series with the first winding and the fourth winding is connected in series with the second winding.
(Item 29)
29. According to item 27 or item 28, wherein the number of first end-turn conductors plus the number of third end-turn conductors is equal to the number of second end-turn conductors plus the number of fourth end-turn conductors. PCS.
(Item 30)
the first end turn conductor comprises a first inner end turn conductor and a first outer end turn conductor;
the second end turn conductor comprises a second inner end turn conductor and a second outer end turn conductor;
each of said first inner end-turn conductors electrically interconnecting a respective pair of portions of said first radial conductors at said first radial distance;
each of said first outer end-turn conductors electrically interconnecting a respective pair of portions of said first radial conductors at said second radial distance;
each of said second inner end-turn conductors electrically interconnecting a respective pair of portions of said first radial conductors at said first radial distance;
each of said second outer end-turn conductors electrically interconnecting a respective pair of portions of said first radial conductors at said second radial distance;
the first subassembly includes the same number of first inner end-turn conductors as second inner end-turn conductors;
30. The PCS of any one of items 26-29, wherein the first subassembly includes more second outer end turn conductors than first outer end turn conductors.

FIG. 1A illustrates the "turn layers" of a planar stator having a winding layout such as that described in U.S. Pat. No. 7,109,625 (the "'625 patent").

FIG. 1B illustrates the "link layer" of a planar stator having a winding layout such as that described in the '625 patent.

FIG. 1C illustrates the link layer shown in FIG. 1B over the turn layer shown in FIG. 1A, with hidden lines removed.

FIG. 2 shows a view of selected portions of a stator configuration having a stack of three six-layer subassemblies.

FIG. 3 shows radial traces at a single angular position across 12 conductive layers of PCS organized in parallel groups of three connected by blind or buried vias.

FIG. 4 shows an inside end-turn of the type described in the '625 patent similar to the inside end-turn shown in FIG. 1A.

Figures 5A and 5B show alternative arrangements of the inner end-turns on the two respective conductive layers of the PCS.

FIG. 6 shows an outer end-turn of the type described in the '625 patent similar to the outer end-turn shown in FIG. 1A.

Figures 7A and 7B show alternative arrangements of the outer end-turns on the two respective conductive layers of the PCS.

FIG. 8 shows the inner and outer end-turns interconnecting the radial traces to form a single coil of the stator, according to the winding layout taught by the '625 patent.

FIG. 9 shows the alternating arrangement of inner and outer end turns for a single phase in plan view of multiple layers.

FIG. 10A shows an enlarged perspective view (in the z-axis) of a subassembly containing four conductive layers, with inner and outer end-turns corresponding to selected phases for clarity. .

FIG. 10B illustrates the location of the inner and outer end-turns for the first phase within the subassembly shown in FIG. 10A.

FIG. 11A illustrates the location of the inner and outer end-turns for the second phase within the subassembly shown in FIG. 10A.

FIG. 11B illustrates the location of the inner and outer end-turns for the third phase within the subassembly shown in FIG. 10A.

FIG. 12A shows an enlarged perspective view (in the z-axis) of an assembly of three subassemblies each similar to the subassembly shown in FIG. 10A.

FIG. 12B illustrates the positions of the inner and outer end-turns for the first phase in the stack of three subassemblies shown in FIG. 12A.

FIG. 13A illustrates the positions of the inner and outer end-turns for the second phase in the stack of three subassemblies shown in FIG. 12A.

FIG. 13B illustrates the positions of the inner and outer end-turns for the third phase in the stack of three subassemblies shown in FIG. 12A.

FIG. 14 shows an enlarged perspective view (in the z-axis) of an exemplary embodiment of a stator employing serpentine windings such as that shown in FIG. 9, with inner end turns of the type shown in FIGS. and outer end-turns of the type shown in FIGS. 7A and 7B are employed to establish all of the winding connections required for the three phases in an assembly containing only two conductive layers.

Figure 15A shows an enlarged perspective view (in the z-axis) of only a portion of the assembly shown in Figure 14 corresponding to the first phase of the stator.

FIG. 15B shows the portion of the upper conductive layer shown in FIG. 15A that contributes to the windings for the first phase.

FIG. 15C shows the portion of the lower conductive layer shown in FIG. 15A that contributes to the windings for the first phase.

Figure 16A illustrates how the windings for the second phase can be made their way through the assembly shown in Figure 14, the parts of the assembly corresponding to the other two phases Removed for illustration purposes.

FIG. 16B illustrates how the windings for the third phase can be made their way through the assembly shown in FIG. Removed for illustration purposes.

Figures 17A and 17B illustrate an example process for forming a multilayer PCS assembly/subassembly.

FIG. 18A illustrates a system in which a PCS such as the one described herein is employed as a stator in an axial flux motor or generator.

Figure 18B illustrates an enlarged view of the system shown in Figure 18A.

For example, a planar composite structure (PCS), which can be used as a stator in axial flux motors or generators, consists of multiple layers of conductive traces (conducting layers). Examples of this type of stator are found in U.S. Pat. No. 7,109,625 (the "'625 patent"), U.S. Pat. 9,673,684, and US Pat. No. 9,800,109, the entire contents of each of which are incorporated herein by reference.

1A-C show plan views of two conductive layers of a planar stator having a winding layout such as that described in the '625 patent. Together, the layers shown establish the inner and outer "end turns" required for a single phase. FIG. 1A shows a single “turn layer” L1 with inner end end-turns 102a and outer end-turns 106 arranging radial traces 104 in the coil, each associated with a pole pair. There are 8 such coils on this 16 pole stator. In the example shown, the coils are helically wound such that the end point of each coil cannot be routed to the start point of subsequent coils on the same layer. This routing difficulty is described in more detail below in connection with FIG. FIG. 1B shows a “link layer” L2 that includes links 108 that serve to connect subsequent coils without interference with turn layer L1. Each of the radial traces 104 on layer L1 is connected to a corresponding (and parallel) radial trace 104 on layer L2 using, for example, vias (not shown). Link layer L2 also includes inner end-turns 102b that overlap inner end-turns 102a in turn layer L1. FIG. 1C shows the link layer L2 above the turn layer L1, with the hidden lines removed. As can be seen, in this configuration the outer end turns 106 and links 108 occupy the same portion of space on the outer radius of the stator. Thus, a three-phase complete stator with a winding layout like that taught by the '625 patent requires a minimum of six conductive layers (ie, three phases x two layers per phase). A balanced stator employing such a winding layout therefore requires multiples of six conductive layers. As used herein, a "balanced stator" refers to a stator in which the electrical load characteristics (in motor mode) or power supply characteristics (in generator mode) of each phase are equal up to a certain electrical phase angle.

With respect to FIGS. 1A-C, certain details of the designs depicted, such as specific structures and/or configurations for heat management and loss reduction (see US Pat. Nos. 9,673,684 and 9,800,109). disclosed, etc.) are not disclosed in the '625 patent. Figures 1A-C therefore show radial traces, inner end turns, outer ends as taught by the '625 patent, rather than the specific structures or configurations that the '625 patent discloses for those elements. Only the end turns and the relative positions of the links are shown.

A stator has been designed in which multiple three-phase balanced stator subassemblies (each with six conducting layers) are stacked on the same planar composite structure (PCS) and connected in parallel. Such a design may increase the ampacity and efficiency of each phase of the stator, for example, because the current for each phase can be carried along parallel paths within the respective subassemblies. FIG. 2 shows a drawing of selected portions of a stator configuration having three six-layer subassemblies stacked in this manner, where a single radial trace 204 (using vias 210) has eighteen conductive traces. The focus is on a single radial trace 204 since it is connected in parallel across the layers. On the last layer L18 two adjacent radial traces 204a, 204b are also shown as a visual guide. The parallel arrangement of radial traces 204 in the active area connected by through vias 210 provides the opportunity to arrange inner and outer windings (as in FIGS. 1A-C) and links across multiple conductive layers. However, since these 18 radial traces are parallel, they can only contribute to a single winding structure.

FIG. 3 is similar to FIG. 2, but shows the structure relevant to the present disclosure. In particular, FIG. 3 shows a radial trace 304 at a single angular position across twelve conductive layers of the PCS. In this case, the radial traces 304 are organized in three parallel groups 312 a , 312 b , 312 c connected by blind or buried vias 310 . For manufacturing reasons, it is most convenient to have multiples of two conductive layers for each of these groups. Unlike a stator constructed according to the '625 patent, each parallel group 312a, 312b, 312c of radial traces 304 is connected in series, thus resulting in a higher number of turns for each coil of the stator. can make it possible. The number of turns for the structure shown in FIG. 3 with three groups of radial traces connected in parallel can be, for example, three times higher than the number of turns for the structure shown in FIG. . Examples of stator implementations in which multiple parallel-connected groups of radial traces are connected in series in such a manner are described below with respect to FIGS. 12A, 12B, 13A, and 13B.

FIG. 4 shows inner end-turns 402 of the type described in the '625 patent, which are similar to the inner end-turns 102 shown in FIG. 1A. These inner end turns 402, together with outer end turns 606 (shown in FIG. 6), are in each radial direction required to establish three windings per pole pair for a single phase. All connections between traces 404 are made. Thus, according to the teachings of the '625 patent, a single end-turn including an inner end-turn 402 such as that shown in FIG. 4 and an outer end-turn 606 (described below) such as that shown in FIG. A conductive layer is required to connect the single phases. For a three-phase board constructed according to this design, a minimum of three such conductive layers are required.

Figures 5A and 5B show an alternative arrangement of inner end-turns 502 on two respective conductive layers L3, L4. that the layer numbers used herein, e.g., "L3", are provided only to enable identification of the various layers being described and do not imply the order in which the various layers are positioned; is intended. In the arrangement shown, radial traces 404 on layer L3 are connected to corresponding traces on layer L4 using, for example, vias (not shown in FIGS. 5A and 5B) similar to vias 310 shown in FIG. When connected in parallel with (and parallel to) radial traces 404, the inner end-turn connections for all of the radial traces 404 shown in FIGS. 5A and 5B are established only on two conductive layers. can be done. As will be described in more detail below, such an arrangement allows inner end-turns 502 for multiple phases to be provided on the same conductive layer, and inner end-turns 502 for the same phase. can be distributed among multiple conductive layers. This contrasts with the configuration of FIG. 4 in which inner end-turns 402 for only a single phase are provided on a given layer and inner end-turns 402 for a given phase are all included on the same conductive layer. In contrast.

Additionally, as discussed in more detail below, in some implementations either one or both of layers L3 and L4 may additionally include, for example, the outer end turns 606 illustrated in FIG. described). Illustrative examples of this type are described below in connection with FIGS. 10A, 10B, 11A, 11B, 12A, 12B, 13A, and 13B. Alternatively, the outer end-turns provided on layers L3 and L4 may be the same as or similar to the outer end-turns 706 described below in connection with FIGS. 7A and 7B. Illustrative examples of the latter type are described below in connection with FIGS. 14, 15A, 15B, 15C, 16A and 16B. Other configurations of outer end-turns on either or both layers L3 and L4, or even configurations in which all outer end-turns are included on layers other than layers L3 and L4, are possible and envisioned. .

Two complementary sets of inner end-turns 502 are shown in FIGS. 5A and 5B, with a first set of inner end-turns 502a, 502b, 502c, 502d, 502e, and 502f on layer L3 in FIG. 5A. A second set of inner end-turns 502g, 502h, 502i, 502j, 502k, 502l are depicted on layer L4 in FIG. 5B. Comparing these complementary connections, the inner end turns 502 for multiple phases can be provided on the same conductive layer, and the inner end turns 502 for a given phase can be between multiple conductive layers. By understanding that they can be distributed, it becomes clear that all the inner end-turn connections required for a three-phase stator can be achieved only within the two layers L3 and L4 shown. For example, a first phase can be supported by inner end-turns 502a and 502d on layer L3 of FIG. 5A and inner end-turns 502h and 502k on layer L4 of FIG. The third phase can be supported by inner end turns 502b and 502e on layer L3 of FIG. 5A and inner end turns 502i and 502l on layer L4 of FIG. It can be supported by end turns 502c and 502f and inner end turns 502g and 502j on layer L4 of FIG. 5B. In such an implementation, the inner end-turns 502 for each phase would consume one-third of layer L3 and one-third of layer L4, so inner end-turns 502 for each phase would consume layer L3 and a total of 2/3 of the tier value of the place on L4. Moreover, in the exemplary implementation shown, a minimum of two conductive layers are required to form a complete inner end-turn connection for all three phases, allowing the stator to balance the inner end-turns. The number of conductive layers should be a multiple of two in order to be

Furthermore, in the exemplary configuration shown in FIGS. 5A and B, there are a total of twelve end turn groups 502a-502l available to establish each pole, so a three-phase stator employing such a configuration Note that each phase of should preferably have four poles. In other words, for densely packed inner end-turn configurations such as those shown in FIGS. ' is an integer).
4 ^* k=3*pole

FIG. 6 shows outer end-turns 606 of the type described in the '625 patent, which are similar to outer end-turns 106 shown in FIG. 1A. These outer end turns 606, together with the inner end turns 402 (shown in FIG. 4), are in respective radial directions required to establish three windings per pole pair for a single phase. All connections between traces 404 are formed. Thus, according to the teachings of the '625 patent, one layer including outer end-turns 606, such as those shown in FIG. 6, and inner end-turns 402, such as those shown in FIG. Required to connect. For a three-phase board constructed according to this design, a minimum of three such conductive layers are required.

Similar to Figures 5A and 5B, Figures 7A and 7B show an alternative arrangement of outer end-turns 706 on the two respective conductive layers L5, L6. In the arrangement shown, radial traces 404 on layer L5 are connected to corresponding traces on layer L6 using, for example, vias (not shown in FIGS. 7A and 7B) similar to vias 310 shown in FIG. When connected in parallel with (and parallel to) radial traces 404, the outer end-turn connections for all of the radial traces 404 shown in FIGS. 7A and 7B are established on only two layers. can. As will be described in more detail below, such an arrangement allows outer end turns 706 for multiple phases to be provided on the same conductive layer, and outer end turns 706 for the same phase. can be distributed among multiple conductive layers. This is the configuration of FIG. 6 where the outer end-turns 606 for only a single phase are provided on a given conductive layer and the outer end-turns 606 for a given phase are all included on the same conductive layer. In contrast to

Additionally, as discussed in more detail below, in some implementations, either or both of layers L5 and L6 may additionally include, for example, inner end turns 402 similar to those shown in FIG. It may contain internal end-turns which may be arranged. Alternatively, the inner end-turns provided on layers L5 and L6 may be the same as or similar to the inner end-turns 502 described above in connection with FIGS. 5A and 5B. Illustrative examples of the latter type are described below in connection with FIGS. 14, 15A, 15B, 15C, 16A and 16B. Other configurations of inner end-turns on either or both layers L5 and L6, or even configurations in which all inner end-turns are included on layers other than layers L5 and L6, are possible and envisioned. .

It should be understood that whatever the implementation, some mechanism would need to be used to somehow get the current into each phase. In the example illustrated in FIGS. 7A and 7B, this uses outer end turn groups 706b, 706c as opposed to other outer end turn groups to establish inputs 708a, 708b, and 708c to the respective winding circuits. , and 706h. In other implementations, the current may additionally or alternatively route the wires from one or more other conductive layers to the outer ends using, for example, vias/solder pads/pressure contacts or pins to dedicated connection layers. It may be introduced in one or more of the phases in some other manner, such as by connecting directly to the inner pad of turn 706, or another similar technique.

Further, in some implementations, current may additionally or alternatively be delivered to each phase from the inner region of the stator, one or more groups of inner end turns, such as those shown in FIGS. 402, 502 are configured differently than the other inner end turn groups to allow inputs similar to inputs 708a, 708b and/or 708c, but instead located within the inner region of the stator. Please understand. Moreover, in some implementations, rather than having the shaft pass through the central region of the stator, the rotor may instead be run "outside" the stator, e.g., an annular or tubular rotor structure surrounds the stator. and rotate around it. For example, in some embodiments such an implementation where current is delivered to each phase from the inner region of the stator may make sense.

Two complementary sets of outer end turns 706 are shown in FIGS. 7A and 7B, with a first set of outer end turns 702a, 702b, 702c, 702d, 702e, and 702f on layer L5 in FIG. 7A. A second set of outer end turns 702g, 702h, 702i, 702j, 702k, 702l are depicted on layer L6 in FIG. 7B. Comparing these complementary connections, the outer end turns 706 for multiple phases can be provided on the same conductive layer, and the outer end turns 706 for a given phase are distributed between multiple conductive layers. By understanding what can be done, it becomes clear that all the required outer end-turn connections for a three-phase stator can be achieved only within the two layers L5 and L6 shown. For example, a first phase can be supported by outer end turns 706a and 706d on layer L5 of FIG. 7A and outer end turns 706h and 706k on layer L6 of FIG. A third phase can be supported by outer end turns 706b and 706e on layer L5 of FIG. 7A and outer end turns 706i and 706l on layer L6 of FIG. It can be supported by end turns 706c and 706f and outer end turns 706g and 706j on layer L6 of FIG. 7B. In such an implementation, the outer end turns 706 for each phase would consume one-third of layer L5 and one-third of layer L6, so that outer end turns 706 for each phase would consume layer L5 and a total of two-thirds of the tier value of the place on L6. Moreover, in the exemplary implementation shown, a minimum of two conductive layers are required to form a complete outer end turn connection for all three phases, allowing the stator to be balanced to the outer end turns. The number of conductive layers should be a multiple of two in order to be

FIG. 8 shows inner end-turns 802 and outer end-turns 806 interconnecting radial traces 804 to form a single coil of the stator, according to the winding layout taught by the '625 patent. The illustrated coil either starts at point 808 and "spirals inward" to point 810 or starts at point 810 and "spirals outward" to point 808. can be seen Note that in this structure there are four inner end-turns 802 but only three outer end-turns 806 . The "missing" outer end turn 806 is the other turn since it needs to establish a connection from the inside of the helix (e.g., point 810) to the outside of the next helix (or vice versa). cannot be routed on the same layer as This type of connection encircles the center point of the stator only once as it progresses around the stator.

FIG. 9 shows the alternating arrangement of inner and outer end-turns for a single phase in plan view of multiple conductive layers. Three windings are provided in the layers shown. In some implementations, inner end-turns 502 such as those shown in FIGS. 5A and 5B may be employed, and those inner end-turns 502 may be distributed across two (or more) conductive layers. In some implementations, for example, the inner end-turns illustrated in FIG. 9 are two groups of inner end-turns 502 from one layer (eg, inner end-turns 502b and 502e on layer L3 shown in FIG. 5A). ) and two groups of inner end-turns 502 from another layer (eg, inner end-turns 502i and 502l on layer L4 shown in FIG. 5B). As discussed above in connection with FIGS. 5A and 5B, the use of inner end-turns 502 from two or more conductive layers allows formation of a complete set of inner end-turn connections for a single phase. can be made possible. Alternatively, in some implementations, some or all of the inner end-turns illustrated in FIG. 9 may be of the type shown in FIG. It can be arranged in layers.

In some implementations, some or all of the outer end-turns illustrated in FIG. 9 may be of the type shown in FIG. can be placed. Alternatively, some or all of the illustrated outer end-turns can be of the type shown in FIG. can be dispersed. In some implementations, for example, the outer end-turns illustrated in FIG. 9 are arranged in two groups of outer end-turns 706 from one conductive layer (eg, the outer end-turns 706a and 706a on layer L5 shown in FIG. 7A). 706d) and two groups of outer end-turns 706 from another conductive layer (eg, outer end-turns 706h and 706k on layer L6 shown in FIG. 7B). As discussed above in connection with FIGS. 7A and 7B, the use of outer end-turns 706 from two or more conductive layers allows formation of a complete set of outer end-turn connections for a single phase. can be made possible.

Whatever the implementation, in contrast to FIG. , 502 equals the number of turns in adjacent groups, and vice versa. The connections from upper right terminal 902, following radial trace 404, inner end-turns 402, 502, and outer end-turns 606, 706 can be routed in a single conductive layer serpentine pattern. to form In the implementation shown in FIG. 8, by contrast, only unconnected windings can be routed within a single conductive layer. As shown in FIG. 9, the serpentine pattern starting at terminal 902 and ending at terminal 904 encircles the center point 906 of the stator three times (or three turns).

10A, 10B, 11A, 11B, 12A, 12B, 13A, and 13B illustrate exemplary embodiments of stators employing serpentine windings such as that shown in FIG. 9 and shown in FIGS. An inner end-turn 502 of the type and an outer end-turn 606 of the type shown in FIG. 6 are employed to establish winding connections for one or more subassemblies each including four conductive layers. Features of a single such subassembly S1 are illustrated in FIGS. Illustrated at 12A, 12B, 13A and 13B. In the example shown in these figures, for each subassembly S1, S2, and S3 shown, each radial connector 404 on a given conductive layer of that subassembly is shown in FIG. In a manner, vias 310 are used to connect to corresponding (and parallel) ones of radial connectors 404 in other conductive layers of that same subassembly. Illustrative techniques for forming multilayer PCS assemblies/subassemblies such as those shown are described below in connection with FIGS. 17A and 17B.

FIG. 10A shows a magnified perspective view (in the z-axis) of subassembly S1 with four conductive layers, inner end-turns 502b, 502e, 502i, 502l and outer end-turn 606, for clarity. Corresponds to the selected phase. The locations of additional inner end-turns 502 and outer end-turns 606 that may be incorporated into the structure of FIG. 10A to establish the other two phases of a three-phase stator are illustrated in FIGS. 11A-11B below. . FIG. 10B is similar to FIG. 10A, but for purposes of illustration additional portions of subassembly S1 corresponding to the other two phases have been removed. FIG. 10B thus illustrates how the windings for a single phase of a three-phase stator can be made their way through a subassembly S1 having four conductive layers.

Similar to FIG. 10B, FIGS. 11A-11B illustrate how the two remaining phase windings may make their way through the subassembly S1 shown in FIG. 10A and for purposes of illustration. In addition, portions of the subassembly corresponding to the other two phases have been removed. Thus, FIG. 10B illustrates the positions of inner end-turns 502b, 502e, 502i, 502l and outer end-turns 606 for the first phase within subassembly S1, and FIG. FIG. 11B illustrates the positions of inner end-turns 502a, 502d, 502h, 502k and outer end-turns 606 for phases 502c, 502f, 502g for the third phase in subassembly S1. , 502i and the positions of the outer end turns 606 are shown.

The inner end-turns 502b, 502e, 502i, 502l for the first phase illustrated in FIGS. 10A and 10B occur at a multiplicity of 2 for the four conductive layers, and the inner end-turns 502b and 502e have four Appearing on two of the layers shown, inner end-turns 502i and 502l appear on the remaining two layers. The same applies to the inner end turns 502 for the other two phases illustrated in Figures 11A and 11B. That is, for the second phase illustrated in FIG. 11A, the inner end-turns 502a, 502d, 502h, 502k occur at a multiplicity of 2 for the four layers, and the inner end-turns 502a and 502d are The inner end-turns 502h and 502k appear on two of the layers to be formed, and the inner end-turns 502h and 502k appear on the remaining two phases, for the third phase illustrated in FIG. 11B, the inner end-turns 502c , 502f, 502g, 502i occur at a multiplicity of 2 for the four layers, inner end-turns 502c and 502f occur on two of the four illustrated layers, inner end-turns 502g and 502i appear on the remaining two layers. Thus, for all three phases of subassembly S1 shown in FIGS. 10A, 10B, 11A, and 11B, the inner end-turns 502 appear at a multiplicity of 2 for the four conductive layers, with subassembly S1 appearing at multiples of 2. It is balanced (equal for each phase) since it has 1 conductive layer.

For the particular phase shown in FIGS. 10A and 10B, namely the first phase, the outer end-turns 606 also appear at a multiplicity of 2 for the four layers shown. For that phase, the outer end turns 606 occupy two of the four conductive layers. Outer end turns 606 (shown in FIGS. 11A and 11B) for the other two phases are on the other two conductive layers, but without redundancy. That is, the outer end-turns 606 (shown in FIG. 11A) for the second phase are single, as are the outer end-turns 606 (shown in FIG. 11B) for the third phase. Appears only on the conductive layer. Thus, subassembly S1 shown in FIGS. 10A, 10B, 11A, and 11B has all the required connections of a three-phase stator, but is balanced by the unequal redundancy of the outer end turns 606 with respect to the phases. do not have.

FIG. 12A shows an enlarged perspective view (in the z-axis) of an assembly of three subassemblies S1, S2, and S3, each similar to the subassembly shown in FIG. 10A. In some embodiments, two or more such respective subassemblies may be laminated together to form a single PCS. As in FIG. 10A, FIG. 12A shows inner end-turns 502 and outer end-turns 606 associated with only one of the three phases for clarity. The locations of additional inner end-turns 502 and outer end-turns 606 that may be incorporated into the structure of FIG. 12A to establish the other two phases of a three-phase stator are illustrated in FIGS. 13A-13B below. .

FIG. 12B is similar to FIG. 12A, but for purposes of illustration additional portions of subassemblies S1, S2 and S3 corresponding to the other two phases have been removed. FIG. 12B thus shows how the windings for a single phase of a three-phase stator are routed through a stacked set of three subassemblies S1, S2, and S3, each subassembly having four conductive layers. Illustrate how you can make those paths. Subassemblies S1, S2, S3 may be electrically connected either in parallel or in series by through vias 1202a, 1202b, 1202c, 1204a, 1204b, 1204c, 1206a, 1206b, and 1206c. In the example shown, the windings of the three subassemblies S1, S2, and S3 are connected in series so that the number of turns for each phase of the overall assembly is equal to the individual subassemblies S1, S2, and Three times greater than the number of turns in any one of S3.

The manner in which current may flow through or between the windings of subassemblies S1, S2, and S3 for the phases illustrated in FIG. 12B will now be described. Although not separately discussed, similar pathways, using different groups of through vias 1202, 1204, and 1206, can be used for winding the other two phases (shown in FIGS. 13A and 13B discussed below). It should be understood that it can be traced for lines. For the phases illustrated in FIG. 12B, current may flow from through via 1202b into the windings of subassembly S1. Current may then exit the windings of subassembly S1 via conductive traces 1208 . Current from conductive trace 1208 may flow through through via 1204b to conductive trace 1210, where it may enter the windings of subassembly S2. Current may then exit the windings of subassembly S2 via conductive traces 1212a and 1212b. Current from conductive traces 1212a, 1212b may then flow through through via 1206b to conductive traces 1214a and 1214b, where it may enter the windings of subassembly S3. The current can then exit the windings of subassembly S3 and flow to the neutral conductor along with the current from the other two phases (shown in FIGS. 13A and 13B).

Similar to FIG. 12B, FIGS. 13A-13B show how the two remaining phase windings can make their way through the three subassemblies S1, S2, and S3 shown in FIG. 12A. , and portions of the subassembly corresponding to the other two phases have been removed for purposes of illustration. Thus, FIG. 12B illustrates the location of inner end-turns 502b, 502e, 502i, and 502l and outer end-turn 606 for the first phase in a stack of three subassemblies S1, S2, and S3, FIG. 13A illustrates the location of inner end-turns 502a, 502d, 502h, and 502k and outer end-turn 606 for the second phase in a stack of three subassemblies S1, S2, and S3, and FIG. 13B. illustrates the location of inner end-turns 502c, 502f, 502g, and 502i and outer end-turn 606 for the third phase in a stack of three subassemblies S1, S2, and S3.

Each subassembly S1, S2, and S3 comprises four conductive layers, as in FIG. 10A, but the phases with outer end-turns 606 of multiplicity 2 within each assembly are different. Thus, for the phase illustrated in FIGS. 12A and 12B, upper subassembly S1 has two parallel layers of outer end turns 606, while the other two subassemblies S2 and S3 do so. Rather, for the phase illustrated in FIG. 13A, the bottom subassembly S3 has two parallel layers of outer end turns 606, while the other two subassemblies S2 and S3 do not. Instead, for the phase illustrated in FIG. 13B, the central subassembly S2 has two parallel layers of outer end turns 606, whereas the other two subassemblies S1 and S3 do not. . Thus, the stacked assembly shown by the combination of FIGS. 12A, 12B, 13A, and 13B has each of the three phases having the same number of parallel and series connected layers of inner end-turns 502 plus , with the same number of parallel and series connected layers of outer windings 606, so that the entire assembly is arranged to be balanced.

Figures 14, 15A, 15B, 15C, 16A, and 16B employ serpentine windings such as those shown in Figure 9, with inner end turns 502 of the type shown in Figures 5A and B, and in Figures 7A and 7B. An exemplary embodiment of a stator in which outer end turns 706 of the type shown are employed to establish all of the required winding connections for the three phases in an assembly containing only two conductive layers. Illustrate. In the example shown in these figures, each of the radial connectors 404 on the upper conductive layer has a corresponding (and parallel) connector in the lower conductive layer using a via 1410 similar to via 310 shown in FIG. a) is connected to the radial connector 404 .

Figure 15A shows an enlarged perspective view (in the z-axis) of only a portion of the assembly shown in Figure 14 corresponding to the first phase of the stator. As shown, the first phase employs inner end-turns 502b, 502e, 502i, 502l shown in FIGS. 5A and 5B and outer end-turns 706a, 706d, 706h, and 706k shown in FIGS. 7A and 7B. can. FIG. 15A thus illustrates how the windings for a single phase of a three-phase stator can be made their way through the assembly shown in FIG. Figures 15B and 15C respectively show the portions of the upper and lower conductive layers shown in Figure 15A that contribute to the windings for the first phase.

Similar to FIG. 15A, FIGS. 16A and 16B illustrate how the windings for the two remaining phases can be made their way through the assembly shown in FIG. Portions of the assembly corresponding to the phases have been removed for purposes of illustration. As shown in FIG. 16A, the second phase includes inner end turns 502a, 502d, 502h, 502k shown in FIGS. 5A and 5B and outer end turns 706c, 706f, 706g shown in FIGS. 706j can be employed. As shown in FIG. 16B, the third phase includes inner end turns 502c, 502f, 502g, 502i shown in FIGS. 5A and 5B and outer end turns 706b, 706e, 706i shown in FIGS. 706l can be employed.

The implementation of two conductive layers shown in Figures 14, 15A, 15B, 16A, and 16B represents a practical limit in reducing the number of layers required for a complete three-phase stator. However, for such a configuration some mechanism would be required to establish electrical connections from the drive circuit (not shown) to locations inside the serpentine windings for each phase. Please understand. For example, referring to FIG. 15A, electrical connections are such as to via 1410a (or another conductor) to allow the drive circuit to establish a complete circuit for the first phase. It would need to be made from a drive circuit. Electrical connection to the other end of the serpentine winding for the first phase can be established using through vias 1402b shown in FIG. 15A. Similarly, referring to FIGS. 16A and 16B, electrical connections are vias 1410b and 1410c, respectively, to allow the drive circuitry to establish a complete circuit for the second and third phases. (or other conductors) would need to be made from the drive circuit.

Such electrical connections include connecting wires directly to the inner pads of the outer end turns through vias/solder pads/pressure contacts or pins to dedicated connection layers, or another similar technique. can be established using any of the mechanisms of Assuming no additional layers are required to provide electrical connection, the greatest advantage of the two conductive layer approach, such as those illustrated in FIGS. The number of windings per layer is three times that of a configuration such as that described in the '625 patent or above with reference to FIGS. can be increased by a factor of two over the configuration described in . This advantage diminishes if additional layers are required, for example, to build a complete stator with neutral connections and terminals outside the outer end turn radius. Additionally, the high density of outer end-turns can impact the ability to use thermal features directly connected to the active area.

Although not shown in the drawings, stacking two or more assemblies similar to those shown in FIGS. It should be understood that either can be connected together as well. In some implementations, for example, the via 1410a shown in FIG. 15A can be connected to another similar assembly having two conductive layers using, for example, one of the connection techniques described in the preceding paragraphs. is connected to the "input" of the serpentine winding of the , thus establishing a series connection to an additional winding for the first phase. In some embodiments, such serpentine windings in the second assembly may, for example, travel in a counterclockwise serpentine path similar to the first assembly, but instead at the outermost outer end It can be rolled “out” towards turn 706 . Additional electrical connections may similarly be established from the outermost end-turns of the second assembly to the input of yet another serpentine winding on yet another assembly having only two conductive layers, the additional The serpentine windings may, for example, travel in a serpentine path, for example counterclockwise, similar to the second assembly, but again may wind "in", similar to the configuration of FIG. 15A. Such a technique of winding "in" and then "out" on each series-connected layer may be repeated any number of times and continue to increase the number of turns for each phase. . In some embodiments, two or more such respective assemblies may be laminated together to form a single planar composite structure (PCS).

17A and 17B illustrate an example process for forming a multilayer PCS assembly/subassembly 1700. FIG. In the example shown, PCS assembly/subassembly 1700 includes four conductive layers CL1, CL2, CL3, and CL4 and three non-conductive dielectric layers DL1, DL2, and DL3. However, it should be understood that the techniques described may additionally or alternatively be used to form PCS subassemblies and/or subassemblies with different numbers of layers.

In some embodiments, two or more dielectric layers DL1, DL2, DL3 may be interleaved with multiple conductive layers CL1, CL2, CL3, CL4 and stacked together. The pattern of conductive traces on each conductive layer CL1, CL2, CL3, CL4 may be arranged to form conductors for one or more circuit elements (e.g., portions of stator windings) and may be made of copper or the like. It can be made of a conductive material. Each conductive layer CL1, CL2, CL3, CL4 may be mechanically supported by at least one dielectric layer DL1, DL2, DL3. A dielectric layer may be formed of a non-conducting material such as fiberglass. Each dielectric layer DL1, DL2, DL3 may thus electrically isolate a respective pair of conductive layers CL1, CL2, CL3, CL4.

The conductor pattern of each conductive layer CL1, CL2, CL3, CL4 can be produced by various methods including, but not limited to, etching, stamping, spraying, cutting, or machining. In some implementations, for example, conductor patterns may be chemically etched into both sides of multiple double-sided circuit boards, each such circuit board comprising two sheets of copper (eg, CL1 in FIG. 17A). and CL2, or CL3 and CL4) sandwiched between a sheet of fiberglass (eg, dielectric layers DL1 or DL3 in FIG. 17A). A plurality of double-sided circuit boards thus formed may then be stacked together with a dielectric (eg, fiberglass) sheet (eg, dielectric layer DL2 in FIG. 17A) sandwiched between each pair. The stacked double-sided circuit boards and fiberglass sheets can then be laminated together using heat and pressure to form a multiple plate array such as that shown in FIG. 17B. As described, the resulting PCS can be used, for example, as a stator for axial flux motors or generators.

In some embodiments, a PCS of the type described above may employ thicker copper sheets than those used in most commonly produced circuit boards. In some implementations, for example, a copper sheet may have a thickness ranging from 0.004 inches to 0.007 inches. Holes 1702 may be drilled into precise locations through one or more (or all) of the circuit boards of PCS 1700, and the inner walls of the holes may be plated with a conductive material such as copper. Plated holes, also known as vias (e.g., blind or buried via 310 shown in FIG. 3 or through vias 1202a, 1202b, 1202c, 1204a, 1204b, 1204c, 1206a, 1206b, and 1206c shown in FIG. 12A) may serve as interlayer conductors that electrically interconnect conductive traces on different conductive layers of the PCS. However, it is understood that other types of inter-layer conductors may additionally or alternatively be employed including, but not limited to, holes filled with conductive material, metal pins, crimp points, spot welds, or wires. want to be Various conductors on different layers of the PCS may be connected together in series and/or in parallel by such vias or other interlayer conductors.

As shown in FIG. 17B, the PCS 1700 may additionally include a central bore 1704 for accommodating the shaft of the rotor of an axial flux motor or generator, as described below.

The assemblies and/or subassemblies described herein may be used in conjunction with the axial flux motor/generator described in the '625 patent and US Patent Nos. 9,673,688, 9,673. , 684, and/or U.S. Pat. No. 9,800,109, the entire contents of which are incorporated by reference above. can be employed in motors or generators that

FIG. 18A shows an example system 1800 employing a planar composite stator 1810 in an assembly with rotor components 1804a and 1804b, shaft 1808, wires 1814, and controller 1812. FIG. An enlarged view showing these components and the means for their assembly is shown in FIG. 18B. The pattern of magnetic poles within the permanently magnetized portions 1806a, 1806b of the rotor assembly is also evident in the enlarged view of FIG. 18B. FIG. 18A is an example of an embodiment in which the electrical connection 1814 is taken at the outer radius of the PCS 1810 and the stator is mounted to the frame or casing at the outer periphery. Another useful configuration, or "outrunner" configuration, is to mount the stator at the inner radius, make the electrical connection 1814 at that inner radius, and attach the shaft 1808 to an annular ring that separates the rotor in half. involves substituting It is also possible to configure the system with only one magnet, either 1806a or 1806b, or to insert multiple stators between successive magnet assemblies. Wires 1814 may also convey information about the position of the rotor based on the readings of Hall effect or similar sensors mounted on the stator. Although not shown, an encoder mounted on shaft 1808 may provide position information to controller 1812 for similar purposes.

The system 1800 of FIGS. 18A and 18B can function as either a motor or a generator, depending on the operation of the controller 1812 and components connected to the shaft 1812. FIG. As a motor system, the controller 1812 operates the switches such that current in the stator 1810 produces torque about the shaft due to magnetic flux in the gap arising from magnets 1804 a, 1804 b connected to the shaft 1808 . Depending on the design of controller 1812 , magnetic flux in the gap and/or rotor position may be measured or estimated to operate switches to achieve torque output at shaft 1808 . As a generator system, a mechanical rotating power source connected to shaft 1808 produces a voltage waveform at terminals 1812 of the stator. These voltages can either be applied directly to the load, or they can be rectified within controller 1812 using a three-phase (or multi-phase) rectifier. The rectifier implementation 1812 can be "self-commutating" using generator mode diodes, or the rectifier implementation 1812 is configured using controlled switches in the motor controller, but the shaft torque is , can be operated such that it opposes the torque provided by the mechanical source and the mechanical energy is converted into electrical energy. Therefore, the same configuration within 18A can function as both a generator and a motor, depending on how the controller 1812 is operated. Additionally, the controller 1812 may include a filter component to mitigate switching effects, reduce EMI/RFI from the wire 1814, reduce losses, and reduce loss supplied to or delivered from the controller. Provides additional flexibility in power consumption.

Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated that various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description and drawings are exemplary only.

Various aspects of the present invention may be used singly or in combination or in various arrangements not specifically discussed within the previously described embodiments and are therefore herein described or described in the foregoing description. The details and arrangements of components illustrated in the drawings are not limiting. For example, aspects described in one embodiment may be combined in any manner with aspects described in other embodiments.

The invention can also be embodied as a method, examples of which are provided. Acts performed as part of a method may be ordered in any suitable manner. Thus, although illustrated as sequential acts in an illustrative embodiment, embodiments may be constructed in which acts are performed in a different order than illustrated, which may include performing certain acts simultaneously.

The use of ordinal terms such as “first,” “second,” “third,” etc. in a claim to modify a claim element may itself refer to one claim element rather than another. does not imply any priority, preference, or order with respect to or chronological order in which the actions of the method are performed, but merely refers to a single claimed element having a given name (barring the use of ordinal terminology) Used as a distinguishing label to distinguish a claim element from other elements with the same name.

Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. "including", "comprising", or "having", "containing", "involving" and their The use of variations of is meant herein to encompass the items listed thereafter, their equivalents, as well as additional items.

(Related application)
This application is based on (A) U.S. patent application Ser. /530,552, filed July 10, 2017, entitled "STRUCTURES AND METHODS OF STACKING SUBASSEMBLIES IN PLANAR COMPOSITE STATORS TO OBTAIN HIGHER WORKING VOLTAGES". The contents of each of the above applications, publications, and patents are hereby incorporated by reference in their entirety for all purposes.

It is known to use planar composite structures (PCS) as stators in axial flux motors or generators. An example of such a stator is described in U.S. Pat. No. 7,109,625 (“the '625 patent”, US Pat.

U.S. Pat. No. 7,109,625

SUMMARY In some embodiments, a planar composite structure (PCS) for use in an axial flux motor or generator comprises a dielectric layer and a first conductive layer disposed on the dielectric layer. The first conductive layer is energized to generate a magnetic flux for a first phase of the motor or generator and a first portion of the first winding to generate a magnetic flux for a first phase of the motor or generator when energized. A first conductive trace forms a first portion of a second winding that produces magnetic flux for the second phase.

In some embodiments, a planar composite structure (PCS) for use in an axial flux motor or generator comprises a dielectric layer, a first conductive layer located on a first side of the dielectric layer; a second conductive layer located on a second side of the dielectric layer. The first conductive layer comprises first conductive traces that, when energized, form a first portion of the windings that produce magnetic flux for a first phase of the motor or generator. A second conductive layer has a second conductive trace forming a second portion of the winding. A first portion of the winding is connected in series with a second portion of the winding, the first and second portions of the winding having the same amount of current flowing through the first and second portions of the winding. configured and arranged to flow through each of the

In some embodiments, a planar composite structure (PCS) for use in an axial flux motor or generator comprises a first conductive layer comprising a first conductive trace and a second conductive trace. a second conductive layer comprising a third conductive trace; a third conductive layer comprising a third conductive trace; and a fourth conductive layer comprising a fourth conductive trace. The first conductive trace includes a first radial conductor extending radially from a first radial distance to a second radial distance that is greater than the first radial distance; The trace includes a second radial conductor extending radially from the first radial distance to a second radial distance, and a third conductive trace extends from the first radial distance to the second radial distance. a third radial conductor radially extending a radial distance; and a fourth conductive trace radially extending a fourth radial distance from the first radial distance to the second radial distance. Includes radial conductors. A first radial conductor is electrically connected to a corresponding one of the second radial conductors by a first blind or buried via, and a third radial conductor is electrically connected to a corresponding one of the second radial conductors by a second blind or buried via. are electrically connected to corresponding ones of the four radial conductors.

In some embodiments, a planar composite structure (PCS) for use in an axial flux motor or generator is radially spaced from a first radial distance to a second radial distance that is greater than the first radial distance. A subassembly having a first conductive layer including a first radial conductor extending in a direction, a first end turn conductor and a second end turn conductor. A first end-turn conductor interconnects a first group of first radial conductors to form a first winding for a first phase of an axial flux motor or generator. A second end-turn conductor interconnects a second group of the first radial conductors to form a second winding for a second phase of the axial flux motor or generator. The first subassembly includes more second end-turn conductors than first end-turn conductors.
The present invention provides, for example, the following.
(Item 1)
A planar composite structure (PCS) for use in an axial flux motor or generator, said PCS comprising:
a dielectric layer;
a first conductive layer disposed on the dielectric layer;
The first conductive layer comprises a first conductive trace, the first conductive trace comprising:
a first portion of a first winding which, when energized, produces a magnetic flux for a first phase of said motor or generator;
and a first portion of a second winding which, when energized, produces magnetic flux for a second phase of said motor or generator.
(Item 2)
The first conductive trace comprises:
First radial conductors, each of said first radial conductors extending radially between at least a first radial distance and a second radial distance greater than said first radial distance. a first radial conductor extending to
a first conductive end-turn;
The PCS of item 1, wherein each of said first conductive end-turns interconnects a respective pair of said first radial conductors.
(Item 3)
the first conductive end-turn comprises a first outer end-turn and a second outer end-turn;
said first outer end turn electrically interconnecting a first pair of portions of said first radial conductor at said second radial distance;
said second outer end turn electrically interconnecting a second pair of portions of said first radial conductor at said second radial distance;
said first portion of said first winding comprises said first outer end-turn;
3. The PCS of item 2, wherein the first portion of the second winding comprises the second outer end-turn.
(Item 4)
the first conductive end-turn comprises a first inner end-turn and a second inner end-turn;
said first inner end turn electrically interconnecting a first pair of portions of said first radial conductor at said first radial distance;
said second inner end turn electrically interconnecting a second pair of portions of said first radial conductor at said first radial distance;
the first portion of the first winding comprises the first inner end-turn;
3. The PCS of item 2, wherein the first portion of the second winding comprises the second inner end-turn.
(Item 5)
the first winding comprises a second portion electrically connected in series with the first portion of the first winding;
said first conductive end-turn further comprising a first outer end-turn;
The first outer end turn comprises a portion of one of the first pair of the first radial conductors at the second radial distance and a portion of the first pair of radial conductors at the second radial distance. electrically interconnecting a portion of another one of the radial conductors;
5. The PCS of item 4, wherein the second portion of the first winding comprises the first outer end-turn.
(Item 6)
Item 5, wherein said first inner end-turn and said first outer end-turn are arranged such that said first portion and second portion of said first winding form a serpentine pattern. PCS described in .
(Item 7)
the first conductive layer on a first side of the dielectric layer;
the PCS further comprising a second conductive layer located on a second side of the dielectric layer;
The second conductive layer comprises a second conductive trace forming a third portion of the first winding, the third portion of the first winding being equal to the first winding. 7. The PCS of item 5 or item 6 connected in series with said second portion of line.
(Item 8)
The second conductive trace comprises:
second radial conductors, each of said second radial conductors radially extending between at least said first radial distance and said second radial distance; a second radial conductor electrically connected to a corresponding one of the radial conductors;
a second conductive end-turn;
8. The PCS of item 7, wherein each of said second conductive end-turns interconnects a respective pair of said second radial conductors.
(Item 9)
the second conductive end-turn comprises a third inner end-turn;
said third inner end turn electrically interconnecting a first pair of portions of said second radial conductor at said first radial distance;
9. The PCS of item 8, wherein the third portion of the first winding comprises the third inner end-turn.
(Item 10)
the first winding comprises a fourth portion electrically connected in series with the third portion of the first winding;
said first conductive end-turn further comprising a second outer end-turn;
said second outer end turn electrically interconnecting a second pair of portions of said second radial conductor at said second radial distance;
10. The PCS of item 8 or item 9, wherein the fourth portion of the first winding comprises the second outer end-turn.
(Item 11)
the first winding comprises a fourth portion electrically connected in series with the third portion of the first winding;
said second conductive end-turn further comprising a second outer end-turn;
The second outer end turn is a portion of one of the first pair of the second radial conductors at the second radial distance and the second radius at the second radial distance. electrically interconnecting a portion of another one of the directional conductors;
10. The PCS of item 8 or item 9, wherein the fourth portion of the first winding comprises the second outer end-turn.
(Item 12)
Item 8, further comprising vias through said dielectric layer, said vias electrically interconnecting each of said second radial conductors with a corresponding one of said first radial conductors. - The PCS of any one of clauses 11.
(Item 13)
13. The PCS of any one of items 8-12, wherein the first winding comprises a first serpentine winding and the second winding comprises a second serpentine winding.
(Item 14)
A planar composite structure (PCS) for use in an axial flux motor or generator, said PCS comprising:
a dielectric layer;
A first conductive layer located on a first side of the dielectric layer, the first conductive layer conducting magnetic flux for a first phase of the motor or generator when energized. a first conductive layer comprising a first conductive trace forming a first portion of the resulting winding;
a second conductive layer located on a second side of said dielectric layer, said second conductive layer comprising a second conductive trace forming a second portion of said winding; a second conductive layer comprising
the first portion of the winding is connected in series with the second portion of the winding;
The PCS, wherein the first and second portions of the winding are constructed and arranged such that the same amount of current flows through each of the first and second portions of the winding.
(Item 15)
The first conductive trace comprises:
First radial conductors, each of said first radial conductors extending radially between at least a first radial distance and a second radial distance greater than said first radial distance. a first radial conductor extending to
a first conductive end-turn;
each of said first conductive end-turns interconnecting a respective pair of said first radial conductors;
The second conductive trace comprises:
second radial conductors, each of said second radial conductors radially extending between at least said first radial distance and said second radial distance; a second radial conductor electrically connected to a corresponding one of the radial conductors;
a second conductive end-turn;
15. The PCS of item 14, wherein each of said second conductive end-turns interconnects a respective pair of said second radial conductors.
(Item 16)
the first conductive end-turn comprises a first inner end-turn;
said first inner end turn electrically interconnecting a first pair of portions of said first radial conductor at said first radial distance;
the first portion of the winding comprises the first inner end-turn;
the second conductive end-turn comprises a second inner end-turn;
said second inner end turn electrically interconnecting a first pair of portions of said second radial conductor at said first radial distance;
16. The PCS of item 15, wherein the second portion of the winding comprises the second inner end-turn.
(Item 17)
the winding further comprises a third portion electrically connected in series between the first portion of the winding and the second portion of the winding;
said first conductive end-turn further comprising a first outer end-turn;
The first outer end turn comprises a portion of one of the first pair of the first radial conductors at the second radial distance and the first radius at the second radial distance. electrically interconnecting a portion of another one of the directional conductors;
17. The PCS of item 16, wherein the third portion of the winding comprises the first outer end-turn.
(Item 18)
The first inner end-turn, the second inner end-turn, and the first outer end-turn are configured such that the first, second, and third portions of the first winding form a serpentine pattern. 18. The PCS of item 17, arranged to.
(Item 19)
the winding comprises a fourth portion electrically connected in series with the second portion of the winding;
said first conductive end-turn further comprising a second outer end-turn;
said second outer end turn electrically interconnecting a second pair of portions of said second radial conductor at said second radial distance;
19. The PCS of item 17 or item 18, wherein the fourth portion of the winding comprises the second outer end-turn.
(Item 20)
the winding comprises a fourth portion electrically connected in series with the second portion of the winding;
said second conductive end-turn further comprising a second outer end-turn;
The second outer end turn is a portion of one of the first pair of the second radial conductors at the second radial distance and the second radius at the second radial distance. electrically interconnecting a portion of another one of the directional conductors;
19. The PCS of item 17 or item 18, wherein the fourth portion of the winding comprises the second outer end-turn.
(Item 21)
further comprising vias through said dielectric layer, said vias electrically interconnecting each of said second radial conductors with a corresponding one of said first radial conductors, items 15-20 PCS according to any one of.
(Item 22)
the first conductive layer is included in a first subassembly of the PCS;
the second conductive layer is included in a second subassembly of the PCS;
the first subassembly includes a third portion of the winding;
the third portion of the winding includes the first portion of the winding;
the third portion of the winding surrounds a first region of the first subassembly at least once;
the second subassembly includes a fourth portion of the winding;
the fourth portion of the winding includes the second portion of the winding;
17. The PCS of any one of items 14-16, wherein the fourth portion of the winding at least once surrounds a second region of the second subassembly.
(Item 23)
A planar composite structure (PCS) for use in an axial flux motor or generator, said PCS comprising:
A first conductive layer comprising a first conductive trace, said first conductive trace being from a first radial distance a second radial distance greater than said first radial distance a first conductive layer comprising a first radial conductor extending radially to
A second conductive layer comprising a second conductive trace, said second conductive trace radially extending from said first radial distance to said second radial distance. a second conductive layer including a second radial conductor;
A third conductive layer comprising a third conductive trace, said third conductive trace radially extending from said first radial distance to said second radial distance a third conductive layer including a third radial conductor;
A fourth conductive layer comprising a fourth conductive trace, said fourth conductive trace radially extending from said first radial distance to said second radial distance a fourth conductive layer comprising a fourth radial conductor;
said first radial conductors being electrically connected to corresponding ones of said second radial conductors by first blind or buried vias;
The PCS, wherein said third radial conductors are electrically connected to corresponding ones of said fourth radial conductors by second blind or buried vias.
(Item 24)
said first conductive trace further comprising first conductive end-turns, each said first conductive end-turn interconnecting a respective pair of said first radial conductors;
said second conductive trace further comprising a second conductive end-turn, each of said second conductive end-turns interconnecting a respective pair of said second radial conductors;
said third conductive trace further comprising a third conductive end-turn, each said third conductive end-turn interconnecting a respective pair of said third radial conductors;
said fourth conductive trace further comprising fourth conductive end-turns, each said fourth conductive end-turn interconnecting a respective pair of said fourth radial conductors; The PCS of item 23.
(Item 25)
The first radial conductor, the second radial conductor, the first conductive end-turn, and the second conductive end-turn are energized to form a first electrical conductor of the motor or generator. establishing an electrical path for a first portion of the winding that produces the magnetic flux for the phase;
The third radial conductor, the fourth radial conductor, the third conductive end-turn, and the fourth conductive end-turn provide an electrical path for a second portion of the winding. establish and
25. The PCS of item 24, wherein the first portion of the winding is connected in series with the second portion of the winding.
(Item 26)
A planar composite structure (PCS) for use in an axial flux motor or generator, said PCS comprising a first subassembly comprising a first conductive layer, said first conductive layer comprising , a first radial conductor extending radially from a first radial distance to a second radial distance greater than said first radial distance; a first end turn conductor; and a second end. turn conductors and
The first end turn conductor interconnects a first group of the first radial conductors to form a first winding for a first phase of the axial flux motor or generator. ,
The second end turn conductor interconnects a second group of the first radial conductors to form a second winding for a second phase of the axial flux motor or generator. ,
The PCS, wherein the first subassembly includes more second end-turn conductors than first end-turn conductors.
(Item 27)
Further comprising a second subassembly comprising a second conductive layer different from said first conductive layer, said second conductive layer comprising a second radial conductor and a third and a fourth end-turn conductor,
The third end turn conductor interconnects the first group of the second radial conductors to form a third winding for a first phase of the axial flux motor or generator. ,
The fourth end turn conductor interconnects a second group of the second radial conductors to form a fourth winding for a second phase of the axial flux motor or generator. ,
27. The PCS of item 26, wherein the first subassembly includes more third end-turn conductors than fourth end-turn conductors.
(Item 28)
28. The PCS of item 27, wherein the third winding is connected in series with the first winding and the fourth winding is connected in series with the second winding.
(Item 29)
29. According to item 27 or item 28, wherein the number of first end-turn conductors plus the number of third end-turn conductors is equal to the number of second end-turn conductors plus the number of fourth end-turn conductors. PCS.
(Item 30)
the first end turn conductor comprises a first inner end turn conductor and a first outer end turn conductor;
the second end turn conductor comprises a second inner end turn conductor and a second outer end turn conductor;
each of said first inner end-turn conductors electrically interconnecting a respective pair of portions of said first radial conductors at said first radial distance;
each of said first outer end-turn conductors electrically interconnecting a respective pair of portions of said first radial conductors at said second radial distance;
each of said second inner end-turn conductors electrically interconnecting a respective pair of portions of said first radial conductors at said first radial distance;
each of said second outer end-turn conductors electrically interconnecting a respective pair of portions of said first radial conductors at said second radial distance;
the first subassembly includes the same number of first inner end-turn conductors as second inner end-turn conductors;
30. The PCS of any one of items 26-29, wherein the first subassembly includes more second outer end turn conductors than first outer end turn conductors.

FIG. 1A illustrates the "turn layers" of a planar stator having a winding layout such as that described in U.S. Pat. No. 7,109,625 (the "'625 patent").

FIG. 1B illustrates the "link layer" of a planar stator having a winding layout such as that described in the '625 patent.

FIG. 1C illustrates the link layer shown in FIG. 1B over the turn layer shown in FIG. 1A, with hidden lines removed.

FIG. 2 shows a view of selected portions of a stator configuration having a stack of three six-layer subassemblies.

FIG. 3 shows radial traces at a single angular position across 12 conductive layers of PCS organized in parallel groups of three connected by blind or buried vias.

FIG. 4 shows an inside end-turn of the type described in the '625 patent similar to the inside end-turn shown in FIG. 1A.

Figures 5A and 5B show alternative arrangements of the inner end-turns on the two respective conductive layers of the PCS.

FIG. 6 shows an outer end-turn of the type described in the '625 patent similar to the outer end-turn shown in FIG. 1A.

Figures 7A and 7B show alternative arrangements of the outer end-turns on the two respective conductive layers of the PCS.

FIG. 8 shows the inner and outer end-turns interconnecting the radial traces to form a single coil of the stator, according to the winding layout taught by the '625 patent.

FIG. 9 shows the alternating arrangement of inner and outer end turns for a single phase in plan view of multiple layers.

FIG. 10A shows an enlarged perspective view (in the z-axis) of a subassembly containing four conductive layers, with inner and outer end-turns corresponding to selected phases for clarity. .

FIG. 10B illustrates the location of the inner and outer end-turns for the first phase within the subassembly shown in FIG. 10A.

FIG. 11A illustrates the location of the inner and outer end-turns for the second phase within the subassembly shown in FIG. 10A.

FIG. 11B illustrates the location of the inner and outer end-turns for the third phase within the subassembly shown in FIG. 10A.

FIG. 12A shows an enlarged perspective view (in the z-axis) of an assembly of three subassemblies each similar to the subassembly shown in FIG. 10A.

FIG. 12B illustrates the positions of the inner and outer end-turns for the first phase in the stack of three subassemblies shown in FIG. 12A.

FIG. 13A illustrates the positions of the inner and outer end-turns for the second phase in the stack of three subassemblies shown in FIG. 12A.

FIG. 13B illustrates the positions of the inner and outer end-turns for the third phase in the stack of three subassemblies shown in FIG. 12A.

FIG. 14 shows an enlarged perspective view (in the z-axis) of an exemplary embodiment of a stator employing serpentine windings such as that shown in FIG. 9, with inner end turns of the type shown in FIGS. and outer end-turns of the type shown in FIGS. 7A and 7B are employed to establish all of the winding connections required for the three phases in an assembly containing only two conductive layers.

Figure 15A shows an enlarged perspective view (in the z-axis) of only a portion of the assembly shown in Figure 14 corresponding to the first phase of the stator.

FIG. 15B shows the portion of the upper conductive layer shown in FIG. 15A that contributes to the windings for the first phase.

FIG. 15C shows the portion of the lower conductive layer shown in FIG. 15A that contributes to the windings for the first phase.

Figure 16A illustrates how the windings for the second phase can be made their way through the assembly shown in Figure 14, the parts of the assembly corresponding to the other two phases Removed for illustration purposes.

FIG. 16B illustrates how the windings for the third phase can be made their way through the assembly shown in FIG. Removed for illustration purposes.

Figures 17A and 17B illustrate an example process for forming a multilayer PCS assembly/subassembly.

FIG. 18A illustrates a system in which a PCS such as the one described herein is employed as a stator in an axial flux motor or generator.

Figure 18B illustrates an enlarged view of the system shown in Figure 18A.

For example, a planar composite structure (PCS), which can be used as a stator in axial flux motors or generators, consists of multiple layers of conductive traces (conducting layers). Examples of this type of stator are found in U.S. Pat. No. 7,109,625 (the "'625 patent"), U.S. Pat. 9,673,684, and US Pat. No. 9,800,109, the entire contents of each of which are incorporated herein by reference.

1A-C show plan views of two conductive layers of a planar stator having a winding layout such as that described in the '625 patent. Together, the layers shown establish the inner and outer "end turns" required for a single phase. FIG. 1A shows a single “turn layer” L1 with inner end end-turns 102a and outer end-turns 106 arranging radial traces 104 in the coil, each associated with a pole pair. There are 8 such coils on this 16 pole stator. In the example shown, the coils are helically wound such that the end point of each coil cannot be routed to the start point of subsequent coils on the same layer. This routing difficulty is described in more detail below in connection with FIG. FIG. 1B shows a “link layer” L2 that includes links 108 that serve to connect subsequent coils without interference with turn layer L1. Each of the radial traces 104 on layer L1 is connected to a corresponding (and parallel) radial trace 104 on layer L2 using, for example, vias (not shown). Link layer L2 also includes inner end-turns 102b that overlap inner end-turns 102a in turn layer L1. FIG. 1C shows the link layer L2 above the turn layer L1, with the hidden lines removed. As can be seen, in this configuration the outer end turns 106 and links 108 occupy the same portion of space on the outer radius of the stator. Thus, a three-phase complete stator with a winding layout like that taught by the '625 patent requires a minimum of six conductive layers (ie, three phases x two layers per phase). A balanced stator employing such a winding layout therefore requires multiples of six conductive layers. As used herein, a "balanced stator" refers to a stator in which the electrical load characteristics (in motor mode) or power supply characteristics (in generator mode) of each phase are equal up to a certain electrical phase angle.

With respect to FIGS. 1A-C, certain details of the designs depicted, such as specific structures and/or configurations for heat management and loss reduction (see US Pat. Nos. 9,673,684 and 9,800,109). disclosed, etc.) are not disclosed in the '625 patent. Figures 1A-C therefore show radial traces, inner end turns, outer ends as taught by the '625 patent, rather than the specific structures or configurations that the '625 patent discloses for those elements. Only the end turns and the relative positions of the links are shown.

A stator has been designed in which multiple three-phase balanced stator subassemblies (each with six conducting layers) are stacked on the same planar composite structure (PCS) and connected in parallel. Such a design may increase the ampacity and efficiency of each phase of the stator, for example, because the current for each phase can be carried along parallel paths within the respective subassemblies. FIG. 2 shows a drawing of selected portions of a stator configuration having three six-layer subassemblies stacked in this manner, where a single radial trace 204 (using vias 210) has eighteen conductive traces. The focus is on a single radial trace 204 since it is connected in parallel across the layers. On the last layer L18 two adjacent radial traces 204a, 204b are also shown as a visual guide. The parallel arrangement of radial traces 204 in the active area connected by through vias 210 provides the opportunity to arrange inner and outer windings (as in FIGS. 1A-C) and links across multiple conductive layers. However, since these 18 radial traces are parallel, they can only contribute to a single winding structure.

FIG. 3 is similar to FIG. 2, but shows the structure relevant to the present disclosure. In particular, FIG. 3 shows a radial trace 304 at a single angular position across twelve conductive layers of the PCS. As shown, each radial trace 304 extends from a first radial distance R1 to a second radial distance R2 that is greater than the first radial distance R1. In this case, the radial traces 304 are organized in three parallel groups 312 a , 312 b , 312 c connected by blind or buried vias 310 . For manufacturing reasons, it is most convenient to have multiples of two conductive layers for each of these groups. Unlike a stator constructed according to the '625 patent, each parallel group 312a, 312b, 312c of radial traces 304 is connected in series, thus resulting in a higher number of turns for each coil of the stator. can make it possible. The number of turns for the structure shown in FIG. 3 with three groups of radial traces connected in parallel can be, for example, three times higher than the number of turns for the structure shown in FIG. . Examples of stator implementations in which multiple parallel-connected groups of radial traces are connected in series in such a manner are described below with respect to FIGS. 12A, 12B, 13A, and 13B.

FIG. 4 illustrates a plurality of radial traces 404 each extending from a first radial distance R1 to a second radial distance R2 greater than the first radial distance R1 and described in the '625 patent. , which are similar to the inner end-turns 102 shown in FIG. 1A. These inner end turns 402, together with outer end turns 606 (shown in FIG. 6), are in each radial direction required to establish three windings per pole pair for a single phase. All connections between traces 404 are formed. Thus, according to the teachings of the '625 patent, a single end-turn including an inner end-turn 402 such as that shown in FIG. 4 and an outer end-turn 606 (described below) such as that shown in FIG. A conductive layer is required to connect the single phases. For a three-phase board constructed according to this design, a minimum of three such conductive layers are required.

Figures 5A and 5B show an alternative arrangement of inner end-turns 502 on two respective conductive layers L3, L4. that the layer numbers used herein, e.g., "L3", are provided only to enable identification of the various layers being described and do not imply the order in which the various layers are positioned; is intended. In the arrangement shown, radial traces 404 on layer L3 are connected to corresponding traces on layer L4 using, for example, vias (not shown in FIGS. 5A and 5B) similar to vias 310 shown in FIG. When connected in parallel with (and parallel to) radial traces 404, the inner end-turn connections for all of the radial traces 404 shown in FIGS. 5A and 5B are established only on two conductive layers. can be done. As will be described in more detail below, such an arrangement allows inner end-turns 502 for multiple phases to be provided on the same conductive layer, and inner end-turns 502 for the same phase. can be distributed among multiple conductive layers. This contrasts with the configuration of FIG. 4 in which inner end-turns 402 for only a single phase are provided on a given layer and inner end-turns 402 for a given phase are all included on the same conductive layer. In contrast.

Additionally, as discussed in more detail below, in some implementations either one or both of layers L3 and L4 may additionally include, for example, the outer end turns 606 illustrated in FIG. described). Illustrative examples of this type are described below in connection with FIGS. 10A, 10B, 11A, 11B, 12A, 12B, 13A, and 13B. Alternatively, the outer end-turns provided on layers L3 and L4 may be the same as or similar to the outer end-turns 706 described below in connection with FIGS. 7A and 7B. Illustrative examples of the latter type are described below in connection with FIGS. 14, 15A, 15B, 15C, 16A and 16B. Other configurations of outer end-turns on either or both layers L3 and L4, or even configurations in which all outer end-turns are included on layers other than layers L3 and L4, are possible and envisioned. .

Two complementary sets of inner end-turns 502 are shown in FIGS. 5A and 5B, with a first set of inner end-turns 502a, 502b, 502c, 502d, 502e, and 502f on layer L3 in FIG. 5A. A second set of inner end-turns 502g, 502h, 502i, 502j, 502k, 502l are depicted on layer L4 in FIG. 5B. Comparing these complementary connections, the inner end turns 502 for multiple phases can be provided on the same conductive layer, and the inner end turns 502 for a given phase can be between multiple conductive layers. By understanding that they can be distributed, it becomes clear that all the inner end-turn connections required for a three-phase stator can be achieved only within the two layers L3 and L4 shown. For example, a first phase can be supported by inner end-turns 502a and 502d on layer L3 of FIG. 5A and inner end-turns 502h and 502k on layer L4 of FIG. The third phase can be supported by inner end turns 502b and 502e on layer L3 of FIG. 5A and inner end turns 502i and 502l on layer L4 of FIG. It can be supported by end turns 502c and 502f and inner end turns 502g and 502j on layer L4 of FIG. 5B. In such an implementation, the inner end-turns 502 for each phase would consume one-third of layer L3 and one-third of layer L4, so inner end-turns 502 for each phase would consume layer L3 and a total of 2/3 of the tier value of the place on L4. Moreover, in the exemplary implementation shown, a minimum of two conductive layers are required to form a complete inner end-turn connection for all three phases, allowing the stator to balance the inner end-turns. The number of conductive layers should be a multiple of two in order to be

Furthermore, in the exemplary configuration shown in FIGS. 5A and B, there are a total of twelve end turn groups 502a-502l available to establish each pole, so a three-phase stator employing such a configuration Note that each phase of should preferably have four poles. In other words, for densely packed inner end-turn configurations such as those shown in FIGS. ' is an integer).
4 ^* k=3*pole

FIG. 6 shows outer end-turns 606 of the type described in the '625 patent, which are similar to outer end-turns 106 shown in FIG. 1A. These outer end turns 606, together with the inner end turns 402 (shown in FIG. 4), are in respective radial directions required to establish three windings per pole pair for a single phase. All connections between traces 404 are formed. Thus, according to the teachings of the '625 patent, one layer including outer end-turns 606, such as those shown in FIG. 6, and inner end-turns 402, such as those shown in FIG. Required to connect. For a three-phase board constructed according to this design, a minimum of three such conductive layers are required.

Similar to Figures 5A and 5B, Figures 7A and 7B show an alternative arrangement of outer end-turns 706 on the two respective conductive layers L5, L6. In the arrangement shown, radial traces 404 on layer L5 are connected to corresponding traces on layer L6 using, for example, vias (not shown in FIGS. 7A and 7B) similar to vias 310 shown in FIG. When connected in parallel with (and parallel to) radial traces 404, the outer end-turn connections for all of the radial traces 404 shown in FIGS. 7A and 7B are established on only two layers. can. As will be described in more detail below, such an arrangement allows outer end turns 706 for multiple phases to be provided on the same conductive layer, and outer end turns 706 for the same phase. can be distributed among multiple conductive layers. This is the configuration of FIG. 6 where the outer end-turns 606 for only a single phase are provided on a given conductive layer and the outer end-turns 606 for a given phase are all included on the same conductive layer. In contrast to

Additionally, as discussed in more detail below, in some implementations, either or both of layers L5 and L6 may additionally include, for example, inner end turns 402 similar to those shown in FIG. It may contain internal end-turns which may be arranged. Alternatively, the inner end-turns provided on layers L5 and L6 may be the same as or similar to the inner end-turns 502 described above in connection with FIGS. 5A and 5B. Illustrative examples of the latter type are described below in connection with FIGS. 14, 15A, 15B, 15C, 16A and 16B. Other configurations of inner end-turns on either or both layers L5 and L6, or even configurations in which all inner end-turns are included on layers other than layers L5 and L6, are possible and envisioned. .

It should be understood that whatever the implementation, some mechanism would need to be used to somehow get the current into each phase. In the example illustrated in FIGS. 7A and 7B, this uses outer end turn groups 706b, 706c as opposed to other outer end turn groups to establish inputs 708a, 708b, and 708c to the respective winding circuits. , and 706h. In other implementations, the current may additionally or alternatively route the wires from one or more other conductive layers to the outer ends using, for example, vias/solder pads/pressure contacts or pins to dedicated connection layers. It may be introduced in one or more of the phases in some other manner, such as by connecting directly to the inner pad of turn 706, or another similar technique.

Further, in some implementations, current may additionally or alternatively be delivered to each phase from the inner region of the stator, one or more groups of inner end turns, such as those shown in FIGS. 402, 502 are configured differently than the other inner end turn groups to allow inputs similar to inputs 708a, 708b and/or 708c, but instead located within the inner region of the stator. Please understand. Moreover, in some implementations, rather than having the shaft pass through the central region of the stator, the rotor may instead be run "outside" the stator, e.g., an annular or tubular rotor structure surrounds the stator. and rotate around it. For example, in some embodiments such an implementation where current is delivered to each phase from the inner region of the stator may make sense.

Two complementary sets of outer end turns 706 are shown in FIGS. 7A and 7B, with a first set of outer end turns 706a, 706b, 706c, 706d, 706e, and 706f on layer L5 in FIG. 7A. A second set of outer end turns 706g, 706h, 706i, 706j, 706k, and 706l are depicted on layer L6 in FIG. 7B. Comparing these complementary connections, the outer end turns 706 for multiple phases can be provided on the same conductive layer, and the outer end turns 706 for a given phase are distributed between multiple conductive layers. By understanding what can be done, it becomes clear that all the required outer end-turn connections for a three-phase stator can be achieved only within the two layers L5 and L6 shown. For example, a first phase can be supported by outer end turns 706a and 706d on layer L5 of FIG. 7A and outer end turns 706h and 706k on layer L6 of FIG. A third phase can be supported by outer end turns 706b and 706e on layer L5 of FIG. 7A and outer end turns 706i and 706l on layer L6 of FIG. It can be supported by end turns 706c and 706f and outer end turns 706g and 706j on layer L6 of FIG. 7B. In such an implementation, the outer end turns 706 for each phase would consume one-third of layer L5 and one-third of layer L6, so that outer end turns 706 for each phase would consume layer L5 and a total of two-thirds of the tier value of the place on L6. Moreover, in the exemplary implementation shown, a minimum of two conductive layers are required to form a complete outer end turn connection for all three phases, allowing the stator to be balanced to the outer end turns. The number of conductive layers should be a multiple of two in order to be

FIG. 8 shows inner end-turns 802 and outer end-turns 806 interconnecting radial traces 804 to form a single coil of the stator, according to the winding layout taught by the '625 patent. The illustrated coil either starts at point 808 and "spirals inward" to point 810 or starts at point 810 and "spirals outward" to point 808. can be seen Note that in this structure there are four inner end-turns 802 but only three outer end-turns 806 . The "missing" outer end turn 806 is the other turn since it needs to establish a connection from the inside of the helix (e.g., point 810) to the outside of the next helix (or vice versa). cannot be routed on the same layer as This type of connection encircles the center point of the stator only once as it progresses around the stator.

FIG. 9 shows the alternating arrangement of inner and outer end-turns for a single phase in plan view of multiple conductive layers. Three windings are provided in the layers shown. In some implementations, inner end-turns 502 such as those shown in FIGS. 5A and 5B may be employed, and those inner end-turns 502 may be distributed across two (or more) conductive layers. In some implementations, for example, the inner end-turns illustrated in FIG. 9 are two groups of inner end-turns 502 from one layer (eg, inner end-turns 502b and 502e on layer L3 shown in FIG. 5A). ) and two groups of inner end-turns 502 from another layer (eg, inner end-turns 502i and 502l on layer L4 shown in FIG. 5B). As discussed above in connection with FIGS. 5A and 5B, the use of inner end-turns 502 from two or more conductive layers allows formation of a complete set of inner end-turn connections for a single phase. can be made possible. Alternatively, in some implementations, some or all of the inner end-turns illustrated in FIG. 9 may be of the type shown in FIG. It can be arranged in layers.

In some implementations, some or all of the outer end-turns illustrated in FIG. 9 may be of the type shown in FIG. can be placed. Alternatively, some or all of the illustrated outer end-turns can be of the type shown in FIG. can be dispersed. In some implementations, for example, the outer end-turns illustrated in FIG. 9 are arranged in two groups of outer end-turns 706 from one conductive layer (eg, the outer end-turns 706a and 706a on layer L5 shown in FIG. 7A). 706d) and two groups of outer end-turns 706 from another conductive layer (eg, outer end-turns 706h and 706k on layer L6 shown in FIG. 7B). As discussed above in connection with FIGS. 7A and 7B, the use of outer end-turns 706 from two or more conductive layers allows formation of a complete set of outer end-turn connections for a single phase. can be made possible.

Whatever the implementation, in contrast to FIG. , 502 equals the number of turns in adjacent groups, and vice versa. The connections from upper right terminal 902, following radial trace 404, inner end-turns 402, 502, and outer end-turns 606, 706 can be routed in a single conductive layer serpentine pattern. to form In the implementation shown in FIG. 8, by contrast, only unconnected windings can be routed within a single conductive layer. As shown in FIG. 9, the serpentine pattern starting at terminal 902 and ending at terminal 904 encircles the center point 906 of the stator three times (or three turns).

10A, 10B, 11A, 11B, 12A, 12B, 13A, and 13B illustrate exemplary embodiments of stators employing serpentine windings such as that shown in FIG. 9 and shown in FIGS. An inner end-turn 502 of the type and an outer end-turn 606 of the type shown in FIG. 6 are employed to establish winding connections for one or more subassemblies each including four conductive layers. Features of a single such subassembly S1 are illustrated in FIGS. Illustrated at 12A, 12B, 13A and 13B. In the example shown in these figures, for each subassembly S1, S2, and S3 shown, each radial connector 404 on a given conductive layer of that subassembly is shown in FIG. In a manner, vias 310 are used to connect to corresponding (and parallel) ones of radial connectors 404 in other conductive layers of that same subassembly. Illustrative techniques for forming multilayer PCS assemblies/subassemblies such as those shown are described below in connection with FIGS. 17A and 17B.

FIG. 10A shows a magnified perspective view (in the z-axis) of subassembly S1 with four conductive layers, inner end-turns 502b, 502e, 502i, 502l and outer end-turn 606, for clarity. Corresponds to the selected phase. The locations of additional inner end-turns 502 and outer end-turns 606 that may be incorporated into the structure of FIG. 10A to establish the other two phases of a three-phase stator are illustrated in FIGS. 11A-11B below. . FIG. 10B is similar to FIG. 10A, but for purposes of illustration additional portions of subassembly S1 corresponding to the other two phases have been removed. FIG. 10B thus illustrates how the windings for a single phase of a three-phase stator can be made their way through a subassembly S1 having four conductive layers.

Similar to FIG. 10B, FIGS. 11A-11B illustrate how the two remaining phase windings may make their way through the subassembly S1 shown in FIG. 10A and for purposes of illustration. In addition, portions of the subassembly corresponding to the other two phases have been removed. Thus, FIG. 10B illustrates the positions of inner end-turns 502b, 502e, 502i, 502l and outer end-turns 606 for the first phase within subassembly S1, and FIG. FIG. 11B illustrates the positions of inner end-turns 502a, 502d, 502h, 502k and outer end-turns 606 for phases 502c, 502f, 502g for the third phase in subassembly S1. , 502 j and the position of the outer end turn 606 are illustrated.

The inner end-turns 502b, 502e, 502i, 502l for the first phase illustrated in FIGS. 10A and 10B occur at a multiplicity of 2 for the four conductive layers, and the inner end-turns 502b and 502e have four Appearing on two of the layers shown, inner end-turns 502i and 502l appear on the remaining two layers. The same applies to the inner end turns 502 for the other two phases illustrated in Figures 11A and 11B. That is, for the second phase illustrated in FIG. 11A, the inner end-turns 502a, 502d, 502h, 502k occur at a multiplicity of 2 for the four layers, and the inner end-turns 502a and 502d are The inner end-turns 502h and 502k appear on two of the layers to be formed, and the inner end-turns 502h and 502k appear on the remaining two phases, for the third phase illustrated in FIG. 11B, the inner end-turns 502c , 502f, 502g, 502j occur at a multiplicity of 2 for the four layers, inner end-turns 502c and 502f occur on two of the four illustrated layers, inner end-turns 502g and 502 j appears on the remaining two layers. Thus, for all three phases of subassembly S1 shown in FIGS. 10A, 10B, 11A, and 11B, the inner end-turns 502 appear at a multiplicity of 2 for the four conductive layers, with subassembly S1 appearing at multiples of 2. It is balanced (equal for each phase) since it has 1 conductive layer.

For the particular phase shown in FIGS. 10A and 10B, namely the first phase, the outer end-turns 606 also appear at a multiplicity of 2 for the four layers shown. For that phase, the outer end turns 606 occupy two of the four conductive layers. Outer end turns 606 (shown in FIGS. 11A and 11B) for the other two phases are on the other two conductive layers, but without redundancy. That is, the outer end-turns 606 (shown in FIG. 11A) for the second phase are single, as are the outer end-turns 606 (shown in FIG. 11B) for the third phase. Appears only on the conductive layer. Thus, subassembly S1 shown in FIGS. 10A, 10B, 11A, and 11B has all the required connections of a three-phase stator, but is balanced by the unequal redundancy of the outer end turns 606 with respect to the phases. do not have.

FIG. 12A shows an enlarged perspective view (in the z-axis) of an assembly of three subassemblies S1, S2, and S3, each similar to the subassembly shown in FIG. 10A. In some embodiments, two or more such respective subassemblies may be laminated together to form a single PCS. As in FIG. 10A, FIG. 12A shows inner end-turns 502 and outer end-turns 606 associated with only one of the three phases for clarity. The locations of additional inner end-turns 502 and outer end-turns 606 that may be incorporated into the structure of FIG. 12A to establish the other two phases of a three-phase stator are illustrated in FIGS. 13A-13B below. .

FIG. 12B is similar to FIG. 12A, but for purposes of illustration additional portions of subassemblies S1, S2 and S3 corresponding to the other two phases have been removed. FIG. 12B thus shows how the windings for a single phase of a three-phase stator are routed through a stacked set of three subassemblies S1, S2, and S3, each subassembly having four conductive layers. Illustrate how you can make those paths. Subassemblies S1, S2, S3 may be electrically connected either in parallel or in series by through vias 1202a, 1202b, 1202c, 1204a, 1204b, 1204c, 1206a, 1206b, and 1206c. In the example shown, the windings of the three subassemblies S1, S2, and S3 are connected in series so that the number of turns for each phase of the overall assembly is equal to the individual subassemblies S1, S2, and Three times greater than the number of turns in any one of S3.

The manner in which current may flow through or between the windings of subassemblies S1, S2, and S3 for the phases illustrated in FIG. 12B will now be described. Although not separately discussed, similar pathways, using different groups of through vias 1202, 1204, and 1206, can be used for winding the other two phases (shown in FIGS. 13A and 13B discussed below). It should be understood that it can be traced for lines. For the phases illustrated in FIG. 12B, current may flow from through via 1202b into the windings of subassembly S1. Current may then exit the windings of subassembly S1 via conductive traces 1208 . Current from conductive trace 1208 may flow through through via 1204b to conductive trace 1210, where it may enter the windings of subassembly S2. Current may then exit the windings of subassembly S2 via conductive traces 1212a and 1212b. Current from conductive traces 1212a, 1212b may then flow through through via 1206b to conductive traces 1214a and 1214b, where it may enter the windings of subassembly S3. The current can then exit the windings of subassembly S3 and flow to the neutral conductor along with the current from the other two phases (shown in FIGS. 13A and 13B).

Similar to FIG. 12B, FIGS. 13A-13B show how the two remaining phase windings can make their way through the three subassemblies S1, S2, and S3 shown in FIG. 12A. , and portions of the subassembly corresponding to the other two phases have been removed for purposes of illustration. Thus, FIG. 12B illustrates the location of inner end-turns 502b, 502e, 502i, and 502l and outer end-turn 606 for the first phase in a stack of three subassemblies S1, S2, and S3, FIG. 13A illustrates the location of inner end-turns 502a, 502d, 502h, and 502k and outer end-turn 606 for the second phase in a stack of three subassemblies S1, S2, and S3, and FIG. 13B. illustrates the positions of the inner end-turns 502c, 502f, 502g, and 502j and the outer end-turn 606 for the third phase in the stack of three subassemblies S1, S2, and S3.

Each subassembly S1, S2, and S3 comprises four conductive layers, as in FIG. 10A, but the phases with outer end-turns 606 of multiplicity 2 within each assembly are different. Thus, for the phase illustrated in FIGS. 12A and 12B, upper subassembly S1 has two parallel layers of outer end turns 606, while the other two subassemblies S2 and S3 do so. Instead, for the phase illustrated in FIG. 13A, the bottom subassembly S3 has two parallel layers of outer end turns 606, while the other two subassemblies S1 and S2 Instead, for the phase illustrated in FIG. 13B, central subassembly S2 has two parallel layers of outer end turns 606, while the other two subassemblies S1 and S3 do so. isn't it. Thus, the stacked assembly shown by the combination of FIGS. 12A, 12B, 13A, and 13B has each of the three phases having the same number of parallel and series connected layers of inner end-turns 502 plus , with the same number of parallel and series connected layers of outer windings 606, so that the entire assembly is arranged to be balanced.

Figures 14, 15A, 15B, 15C, 16A, and 16B employ serpentine windings such as those shown in Figure 9, with inner end turns 502 of the type shown in Figures 5A and B, and in Figures 7A and 7B. An exemplary embodiment of a stator in which outer end turns 706 of the type shown are employed to establish all of the required winding connections for the three phases in an assembly containing only two conductive layers. Illustrate. In the example shown in these figures, each of the radial connectors 404 on the upper conductive layer has a corresponding (and parallel) connector in the lower conductive layer using a via 1410 similar to via 310 shown in FIG. a) is connected to the radial connector 404 .

Figure 15A shows an enlarged perspective view (in the z-axis) of only a portion of the assembly shown in Figure 14 corresponding to the first phase of the stator. As shown, the first phase employs inner end-turns 502b, 502e, 502i, 502l shown in FIGS. 5A and 5B and outer end-turns 706a, 706d, 706h, and 706k shown in FIGS. 7A and 7B. can. FIG. 15A thus illustrates how the windings for a single phase of a three-phase stator can be made their way through the assembly shown in FIG. Figures 15B and 15C respectively show the portions of the upper and lower conductive layers shown in Figure 15A that contribute to the windings for the first phase.

Similar to FIG. 15A, FIGS. 16A and 16B illustrate how the windings for the two remaining phases can be made their way through the assembly shown in FIG. Portions of the assembly corresponding to the phases have been removed for purposes of illustration. As shown in FIG. 16A, the second phase includes inner end turns 502a, 502d, 502h, 502k shown in FIGS. 5A and 5B and outer end turns 706c, 706f, 706g shown in FIGS. 706j can be employed. As shown in FIG. 16B, the third phase includes inner end turns 502c, 502f, 502g, 502j shown in FIGS. 5A and 5B and outer end turns 706b, 706e, 706i shown in FIGS. and 706l.

The implementation of two conductive layers shown in Figures 14, 15A, 15B, 16A, and 16B represents a practical limit in reducing the number of layers required for a complete three-phase stator. However, for such a configuration some mechanism would be required to establish electrical connections from the drive circuit (not shown) to locations inside the serpentine windings for each phase. Please understand. For example, referring to FIG. 15A, electrical connections are made such as to via 1410 b (or another conductor) to allow the drive circuit to establish a complete circuit for the first phase. would need to be made from a flexible drive circuit. Electrical connection to the other end of the serpentine winding for the first phase can be established using through vias 1402b shown in FIG. 15A. Similarly, referring to FIGS. 16A and 16B, electrical connections are vias 1410c and 1410c , respectively, to allow the drive circuitry to establish a complete circuit for the second and third phases. 1410a (or other conductor) would need to be made from the drive circuit. Electrical connections to the other ends of the serpentine windings for the second and third phases can be established using through vias 1402c and 1402a shown in FIGS. 16A and 16B, respectively.

Such electrical connections include connecting wires directly to the inner pads of the outer end turns through vias/solder pads/pressure contacts or pins to dedicated connection layers, or another similar technique. can be established using any of the mechanisms of Assuming no additional layers are required to provide electrical connection, the greatest advantage of the two conductive layer approach, such as those illustrated in FIGS. The number of windings per layer is three times that of a configuration such as that described in the '625 patent or above with reference to FIGS. can be increased by a factor of two over the configuration described in . This advantage diminishes if additional layers are required, for example, to build a complete stator with neutral connections and terminals outside the outer end turn radius. Additionally, the high density of outer end-turns can impact the ability to use thermal features directly connected to the active area.

Although not shown in the drawings, stacking two or more assemblies similar to those shown in FIGS. It should be understood that either can be connected together as well. In some implementations, for example, the via 1410a shown in FIG. 15A can be connected to another similar assembly having two conductive layers using, for example, one of the connection techniques described in the preceding paragraphs. is connected to the "input" of the serpentine winding of the , thus establishing a series connection to an additional winding for the first phase. In some embodiments, such serpentine windings in the second assembly may, for example, travel in a counterclockwise serpentine path similar to the first assembly, but instead at the outermost outer end It can be rolled “out” towards turn 706 . Additional electrical connections may similarly be established from the outermost end-turns of the second assembly to the input of yet another serpentine winding on yet another assembly having only two conductive layers, the additional The serpentine windings may, for example, travel in a serpentine path, for example counterclockwise, similar to the second assembly, but again may wind "in", similar to the configuration of FIG. 15A. Such a technique of winding "in" and then "out" on each series-connected layer may be repeated any number of times and continue to increase the number of turns for each phase. . In some embodiments, two or more such respective assemblies may be laminated together to form a single planar composite structure (PCS).

17A and 17B illustrate an example process for forming a multilayer PCS assembly/subassembly 1700. FIG. In the example shown, PCS assembly/subassembly 1700 includes four conductive layers CL1, CL2, CL3, and CL4 and three non-conductive dielectric layers DL1, DL2, and DL3. However, it should be understood that the techniques described may additionally or alternatively be used to form PCS subassemblies and/or subassemblies with different numbers of layers.

In some embodiments, two or more dielectric layers DL1, DL2, DL3 may be interleaved with multiple conductive layers CL1, CL2, CL3, CL4 and stacked together. The pattern of conductive traces on each conductive layer CL1, CL2, CL3, CL4 may be arranged to form conductors for one or more circuit elements (e.g., portions of stator windings) and may be made of copper or the like. It can be made of a conductive material. Each conductive layer CL1, CL2, CL3, CL4 may be mechanically supported by at least one dielectric layer DL1, DL2, DL3. A dielectric layer may be formed of a non-conducting material such as fiberglass. Each dielectric layer DL1, DL2, DL3 may thus electrically isolate a respective pair of conductive layers CL1, CL2, CL3, CL4.

The conductor pattern of each conductive layer CL1, CL2, CL3, CL4 can be produced by various methods including, but not limited to, etching, stamping, spraying, cutting, or machining. In some implementations, for example, conductor patterns may be chemically etched into both sides of multiple double-sided circuit boards, each such circuit board comprising two sheets of copper (eg, CL1 in FIG. 17A). and CL2, or CL3 and CL4) sandwiched between a sheet of fiberglass (eg, dielectric layers DL1 or DL3 in FIG. 17A). A plurality of double-sided circuit boards thus formed may then be stacked together with a dielectric (eg, fiberglass) sheet (eg, dielectric layer DL2 in FIG. 17A) sandwiched between each pair. The stacked double-sided circuit boards and fiberglass sheets can then be laminated together using heat and pressure to form a multiple plate array such as that shown in FIG. 17B. As described, the resulting PCS can be used, for example, as a stator for axial flux motors or generators.

In some embodiments, a PCS of the type described above may employ thicker copper sheets than those used in most commonly produced circuit boards. In some implementations, for example, a copper sheet may have a thickness ranging from 0.004 inches to 0.007 inches. Holes 1702 may be drilled into precise locations through one or more (or all) of the circuit boards of PCS 1700, and the inner walls of the holes may be plated with a conductive material such as copper. Plated holes, also known as vias (e.g., blind or buried via 310 shown in FIG. 3 or through vias 1202a, 1202b, 1202c, 1204a, 1204b, 1204c, 1206a, 1206b, and 1206c shown in FIG. 12A) may serve as interlayer conductors that electrically interconnect conductive traces on different conductive layers of the PCS. However, it is understood that other types of inter-layer conductors may additionally or alternatively be employed including, but not limited to, holes filled with conductive material, metal pins, crimp points, spot welds, or wires. want to be Various conductors on different layers of the PCS may be connected together in series and/or in parallel by such vias or other interlayer conductors.

As shown in FIG. 17B, the PCS 1700 may additionally include a central bore 1704 for accommodating the shaft of the rotor of an axial flux motor or generator, as described below.

The assemblies and/or subassemblies described herein may be used in conjunction with the axial flux motor/generator described in the '625 patent and US Patent Nos. 9,673,688, 9,673. , 684, and/or U.S. Pat. No. 9,800,109, the entire contents of which are incorporated by reference above. can be employed in motors or generators that

FIG. 18A shows an example system 1800 employing a planar composite stator 1810 in an assembly with rotor components 1804a and 1804b, shaft 1808, screw 1802 , wires 1814, and controller 1812. FIG. An enlarged view showing these components and the means for their assembly is shown in FIG. 18B. The pattern of magnetic poles within the permanently magnetized portions 1806a, 1806b of the rotor assembly is also evident in the enlarged view of FIG. 18B. FIG. 18A is an example of an embodiment in which the electrical connection 1814 is taken at the outer radius of the PCS 1810 and the stator is mounted to the frame or casing at the outer periphery. Another useful configuration, or "outrunner" configuration, is to mount the stator at the inner radius, make the electrical connection 1814 at that inner radius, and attach the shaft 1808 to an annular ring that separates the rotor in half. involves substituting It is also possible to configure the system with only one magnet, either 1806a or 1806b, or to insert multiple stators between successive magnet assemblies. Wires 1814 may also convey information about the position of the rotor based on the readings of Hall effect or similar sensors mounted on the stator. Although not shown, an encoder mounted on shaft 1808 may provide position information to controller 1812 for similar purposes.

The system 1800 of FIGS. 18A and 18B can function as either a motor or a generator, depending on the operation of the controller 1812 and components connected to the shaft 1812. FIG. As a motor system, the controller 1812 switches so that the current in the stator 1810 produces a torque about the shaft due to the magnetic flux in the gap resulting from magnets 180 6 a, 180 6 b connected to the shaft 1808. make it work. Depending on the design of controller 1812 , magnetic flux in the gap and/or rotor position may be measured or estimated to operate switches to achieve torque output at shaft 1808 . As a generator system, a mechanical rotating power source connected to shaft 1808 produces a voltage waveform at terminals 1812 of the stator. These voltages can either be applied directly to the load, or they can be rectified within controller 1812 using a three-phase (or multi-phase) rectifier. The rectifier implementation 1812 can be "self-commutating" using generator mode diodes, or the rectifier implementation 1812 is configured using controlled switches in the motor controller, but the shaft torque is , can be operated such that it opposes the torque provided by the mechanical source and the mechanical energy is converted into electrical energy. Therefore, the same configuration within 18A can function as both a generator and a motor, depending on how the controller 1812 is operated. Additionally, the controller 1812 may include a filter component to mitigate switching effects, reduce EMI/RFI from the wire 1814, reduce losses, and reduce loss supplied to or delivered from the controller. Provides additional flexibility in power consumption.

Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated that various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description and drawings are exemplary only.

Various aspects of the present invention may be used singly or in combination or in various arrangements not specifically discussed within the previously described embodiments and are therefore herein described or described in the foregoing description. The details and arrangements of components illustrated in the drawings are not limiting. For example, aspects described in one embodiment may be combined in any manner with aspects described in other embodiments.

The invention can also be embodied as a method, examples of which are provided. Acts performed as part of a method may be ordered in any suitable manner. Thus, although illustrated as sequential acts in an illustrative embodiment, embodiments may be constructed in which acts are performed in a different order than illustrated, which may include performing certain acts simultaneously.

The use of ordinal terms such as “first,” “second,” “third,” etc. in a claim to modify a claim element may itself refer to one claim element rather than another. does not imply any priority, preference, or order with respect to or chronological order in which the actions of the method are performed, but merely refers to a single claimed element having a given name (barring the use of ordinal terminology) Used as a distinguishing label to distinguish a claim element from other elements with the same name.

Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. "including", "comprising", or "having", "containing", "involving" and their The use of variations of is meant herein to encompass the items listed thereafter, their equivalents, as well as additional items.

Claims (7)

A planar composite structure (PCS) for use in an axial flux motor or generator, said PCS comprising:
a first dielectric layer;
A first conductive layer on a first side of the first dielectric layer, the first conductive layer comprising a first conductive trace, the first conductive trace comprising:
a first radial conductor radially extending from a first radial distance to a second radial distance greater than the first radial distance;
a first conductive end-turn, each of said first conductive end-turns interconnecting a respective pair of said first radial conductors; a first conductive layer comprising;
a second conductive layer on a second side of the first dielectric layer, the second conductive layer comprising a second conductive trace, the second conductive trace comprising:
a second radial conductor radially extending from the first radial distance to the second radial distance;
second conductive end-turns, each of said second conductive end-turns interconnecting a respective pair of said second radial conductors; a second conductive layer comprising;
first blind or buried vias through said first dielectric layer, each of said first radial conductors passing through at least one respective first blind or buried via and said second radial conductors a first blind or buried via electrically connected to a corresponding one of
a second dielectric layer;
a third conductive layer on the first side of the second dielectric layer, the third conductive layer comprising a third conductive trace, the third conductive trace comprising:
a third radial conductor extending radially from the first radial distance to the second radial distance;
third conductive end-turns, each of said third conductive end-turns interconnecting a respective pair of said third radial conductors; a third conductive layer comprising;
a fourth conductive layer on the second side of the second dielectric layer, the fourth conductive layer comprising a fourth conductive trace, the fourth conductive trace comprising:
a fourth radial conductor radially extending from the first radial distance to the second radial distance;
fourth conductive end-turns, each of said fourth conductive end-turns interconnecting a respective pair of said fourth radial conductors; a fourth conductive layer comprising;
second blind or buried vias through said second dielectric layer, each said third radial conductor through at least one respective second blind or buried via, said fourth radial conductor a second blind or buried via electrically connected to a corresponding one of
and a third dielectric layer between said second conductive layer and said third conductive layer. The first radial conductor, the second radial conductor, the first conductive end-turn, and the second conductive end-turn are energized to generate a first phase of the motor or generator. establishing an electrical path for the first portion of the winding that produces a magnetic flux for
The third radial conductor, the fourth radial conductor, the third conductive end-turn, and the fourth conductive end-turn provide an electrical path for a second portion of the winding. establish and
2. The PCS of claim 1 , wherein the first portion of the winding is connected in series with the second portion of the winding. A planar composite structure (PCS) for use in an axial flux motor or generator, said PCS comprising a first subassembly comprising a first conductive layer, said first conductive layer comprising , a first radial conductor extending radially from a first radial distance to a second radial distance greater than said first radial distance; a first end turn conductor; and a second end. turn conductors and
The first end turn conductor interconnects a first group of the first radial conductors to form a first winding for a first phase of the axial flux motor or generator. ,
The second end turn conductor interconnects a second group of the first radial conductors to form a second winding for a second phase of the axial flux motor or generator. ,
The PCS, wherein the first subassembly includes more second end-turn conductors than first end-turn conductors. a second subassembly, said second subassembly comprising a second conductive layer different from said first conductive layer, said second conductive layer comprising a second radial conductor; three end-turn conductors and a fourth end-turn conductor;
The third end turn conductor interconnects the first group of the second radial conductors to form a third winding for a first phase of the axial flux motor or generator. ,
The fourth end turn conductor interconnects a second group of the second radial conductors to form a fourth winding for a second phase of the axial flux motor or generator. ,
4. The PCS of claim 3 , wherein the first subassembly includes more third end-turn conductors than fourth end-turn conductors. the third winding is connected in series with the first winding;
5. The PCS of claim 4 , wherein the fourth winding is connected in series with the second winding. 6. The number of said first end-turn conductors plus the number of said third end-turn conductors is equal to the number of said second end-turn conductors plus the number of said fourth end-turn conductors. PCS described in . the first end turn conductor comprises a first inner end turn conductor and a first outer end turn conductor;
the second end turn conductor comprises a second inner end turn conductor and a second outer end turn conductor;
each of said first inner end-turn conductors electrically interconnecting a respective pair of portions of said first radial conductors at said first radial distance;
each of said first outer end-turn conductors electrically interconnecting a respective pair of portions of said first radial conductors at said second radial distance;
each of said second inner end-turn conductors electrically interconnecting a respective pair of portions of said first radial conductors at said first radial distance;
each of said second outer end-turn conductors electrically interconnecting a respective pair of portions of said first radial conductors at said second radial distance;
the first subassembly includes the same number of first inner end-turn conductors as second inner end-turn conductors;
7. The PCS of any one of claims 3 to 6 , wherein the first subassembly includes more second outer end-turn conductors than first outer end-turn conductors.

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