The present invention relates to an improved stator for an axial field rotary energy device operating as a motor or a generator as described in U.S. Pat. No. 7,109,625 to Jore et al.
The size of machines that may be produced with a one-piece printed circuit board (PCB) stator is limited by the capability of the processing equipment found in a PCB manufacturing facility. High volume facilities have a maximum size PCB panel that can be processed on automated equipment. Certain lower volume facilities routinely process larger PCB panel sizes than the high volume manufacturers but there is a higher cost due to more labor and higher material costs. In order to cost effectively produce large axial field rotary machines that incorporate a PCB stator, a segmented PCB stator is shown and described. The segments allow a much larger diameter machine than is possible with single piece PCB stator designs. Further, the segments may be produced in high volume manufacturing facilities that provide the best cost.
The present invention provides an axial rotary energy device which is arranged in a multi-phase electric current configuration. The device includes a rotor having a plurality of permanent magnet poles secured thereto and further includes a segmented stator assembly having a plurality of segments arranged in an annular array. Each stator segment is constructed by stacking a plurality of printed circuit board power conductor layers together with a plurality of much larger diameter machine than is possible with single piece PCB stator designs. Further, the segments may be produced in high volume manufacturing facilities that provide the best cost.
The present invention provides an axial rotary energy device which is arranged in a multi-phase electric current configuration. The device includes a rotor having a plurality of permanent magnet poles secured thereto and further includes a segmented stator assembly having a plurality of segments arranged in an annular array. Each stator segment is constructed by stacking a plurality of printed circuit board power conductor layers together with a plurality of printed circuit board series layers. Each stator segment having at least one working power conductor layer for each phase of the electric current and at least one series conductor layer associated with one power conductor layer. Each power conductor layer and series conductor layer having radial conductors extending from an inner diameter via to an outer diameter via. The vias are provided for electrically connecting selected ones of the radial conductors of the series conductor layer to selected ones of the radial conductors of the power conductor layer. Each power conductor layer includes a pair of positive and negative terminal vias for one phase of the electric current connected to selected outer vias of the power conductor layer. A daughter printed circuit board is used for electrically connecting two adjacent segments together. Each daughter printed circuit board having a first portion electrically connected to a negative terminal via located in one segment and a second portion electrically connected to a positive terminal via located in an adjacent segment. A current conductor is provided on the daughter printed circuit board for electrically connecting the negative terminal via and the positive terminal via together.
In order that the invention may be clearly understood and readily carried into effect, a preferred embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings wherein:
An axial gap device 10 according to the present invention is shown in
Continuing in
In
As seen in
Continuing in
The patterns and electrical current flow is similar for the power and series layers for. phase B and phase C.
The multiple layer stator segments 32 of the annular array comprising the entire stator are constructed by stacking the individual stator power segments 32A and stator series segments 32B for the A, B and C phases one on top the other with a substitute dielectric layer 33 provided between each layer. The stacking order of the stator power segments 32A and the stator series segments 32B for phases A, B and C is selectable. There may be duplicates of each layer type in the stator segment. There may be a greater number of series layers than power layers in the stator segment. The order of the layers is preferably selected to provide an even distribution of electrical current throughout different layers of the stator segment and particularly so that there is an even distribution of electrical current through the axial length of the inner and outer vias. The main benefit of the even distribution of the electrical current is to optimize the thermal dissipation of the stator segment 32. The durability of each stator segment 32 is enhanced by reducing the thermal stress that can cause delamination of the layers and cracking in the walls of the vias.
As a non-limiting example, a stator segment with eighteen layers might have two power layers for phase A, four series layers for phase A, two power layers for phase B, four series layers for phase B, two power layers for phase C, and four series layers for phase C.
The daughter printed circuit boards 36 are used to electrically connect adjacent stator segments 32 together. As shown in
While the fundamental novel features of the invention have been shown and described, it should be understood that various substitutions, modifications, and variations may be made by those skilled in the arts, without departing from the spirit or scope of the invention. Accordingly, all such modifications or variations are included in the scope of the invention as defined by the following claims:
This application is a continuation of U.S. patent application Ser. No. 13/144,642, having a 371(c) date of Jul. 14, 2011, and entitled “Segmented Stator for an Axial Field Device,” now U.S. Pat. No. 8,823,241, which is a National Stage Entry under 35 U.S.C. §371 of PCT/US2010/000112, filed Jan. 15, 2010, and entitled “Segmented Stator for an Axial Field Device,” which claims priority to and the benefit of U.S. Provisional Patent Application No. 61/205,435, filed Jan. 16, 2009, and entitled “Segmented Stator for an Axial Field Machine.”
Number | Name | Date | Kind |
---|---|---|---|
3521091 | Halas | Jul 1970 | A |
3641429 | Cox, Jr. et al. | Feb 1972 | A |
3719845 | Takeda | Mar 1973 | A |
3793530 | Carter | Feb 1974 | A |
3796039 | Lucien | Mar 1974 | A |
3845339 | Merkle et al. | Oct 1974 | A |
4035659 | Jeppson | Jul 1977 | A |
4096625 | Morreale | Jun 1978 | A |
4168439 | Palma | Sep 1979 | A |
4242628 | Mohan et al. | Dec 1980 | A |
4261441 | Wood | Apr 1981 | A |
4281965 | Stjernholm | Aug 1981 | A |
4291233 | Kirschbaum | Sep 1981 | A |
4292532 | Leroux | Sep 1981 | A |
4318019 | Teasley et al. | Mar 1982 | A |
4336475 | Morinaga et al. | Jun 1982 | A |
4418287 | Syverson | Nov 1983 | A |
4634912 | Heyraud | Jan 1987 | A |
4658162 | Koyama et al. | Apr 1987 | A |
4677332 | Heyraud | Jun 1987 | A |
4720640 | Anderson et al. | Jan 1988 | A |
4733115 | Barone et al. | Mar 1988 | A |
4763053 | Rabe | Aug 1988 | A |
4804574 | Osawa et al. | Feb 1989 | A |
4906060 | Claude | Mar 1990 | A |
4970404 | Barger | Nov 1990 | A |
4992920 | Davis | Feb 1991 | A |
4994684 | Lauw et al. | Feb 1991 | A |
5028804 | Lauw | Jul 1991 | A |
5083077 | Wallace et al. | Jan 1992 | A |
5097167 | Kanayama et al. | Mar 1992 | A |
5099162 | Sawada | Mar 1992 | A |
5237230 | Sugiyama et al. | Aug 1993 | A |
5239251 | Lauw | Aug 1993 | A |
5260617 | Leibowitz | Nov 1993 | A |
5289042 | Lis | Feb 1994 | A |
5299913 | Heidelberg | Apr 1994 | A |
5315159 | Gribnau | May 1994 | A |
5370711 | Audit et al. | Dec 1994 | A |
5418446 | Hallidy | May 1995 | A |
5439488 | Audit et al. | Aug 1995 | A |
5506453 | McCombs | Apr 1996 | A |
5525894 | Heller | Jun 1996 | A |
5587643 | Heller | Dec 1996 | A |
5589722 | Sakaguchi et al. | Dec 1996 | A |
5619085 | Shramo | Apr 1997 | A |
5637945 | Yamamuro et al. | Jun 1997 | A |
5723933 | Grund et al. | Mar 1998 | A |
5783894 | Wither | Jul 1998 | A |
5798631 | Spee et al. | Aug 1998 | A |
5798632 | Muljadi | Aug 1998 | A |
5841208 | Abe | Nov 1998 | A |
5842312 | Krumme et al. | Dec 1998 | A |
5844324 | Spriggle | Dec 1998 | A |
5844341 | Spooner et al. | Dec 1998 | A |
5986438 | Wallace et al. | Nov 1999 | A |
6016015 | Willard, Jr. | Jan 2000 | A |
6040650 | Rao | Mar 2000 | A |
6064123 | Gislason | May 2000 | A |
6066945 | Shimazu et al. | May 2000 | A |
6072303 | Nickoladze et al. | Jun 2000 | A |
6097104 | Russell et al. | Aug 2000 | A |
6153944 | Clark | Nov 2000 | A |
6157147 | Lin | Dec 2000 | A |
6160336 | Baker, Jr. et al. | Dec 2000 | A |
6163097 | Smith et al. | Dec 2000 | A |
6163137 | Wallace et al. | Dec 2000 | A |
6172429 | Russell | Jan 2001 | B1 |
6177735 | Chapman et al. | Jan 2001 | B1 |
6215199 | Lysenko et al. | Apr 2001 | B1 |
6246125 | Axtell | Jun 2001 | B1 |
6249058 | Rea | Jun 2001 | B1 |
6278197 | Appa | Aug 2001 | B1 |
6285090 | Brutsaert et al. | Sep 2001 | B1 |
6327994 | Labrador | Dec 2001 | B1 |
6359401 | Garcia-Sinclair et al. | Mar 2002 | B1 |
6373161 | Khalaf | Apr 2002 | B1 |
6392371 | Cheng et al. | May 2002 | B1 |
6411002 | Smith et al. | Jun 2002 | B1 |
6412237 | Sahai | Jul 2002 | B1 |
6426580 | Ikeda et al. | Jul 2002 | B1 |
6429552 | Asao et al. | Aug 2002 | B2 |
6452287 | Looker | Sep 2002 | B1 |
6476513 | Gueorguiev | Nov 2002 | B1 |
6476534 | Vanderbeck et al. | Nov 2002 | B1 |
6476535 | Oohashi et al. | Nov 2002 | B1 |
6483199 | Umemoto et al. | Nov 2002 | B2 |
6504260 | Debleser | Jan 2003 | B1 |
6522045 | Ikeda et al. | Feb 2003 | B2 |
6522046 | Ikeda et al. | Feb 2003 | B2 |
6541877 | Kim et al. | Apr 2003 | B2 |
6598573 | Kobayashi | Jul 2003 | B2 |
6641367 | Van der Klippe | Nov 2003 | B1 |
6661146 | Oohashi et al. | Dec 2003 | B2 |
6664704 | Calley | Dec 2003 | B2 |
6665990 | Cody | Dec 2003 | B1 |
6693409 | Lynch et al. | Feb 2004 | B2 |
6700278 | Ehrfeld et al. | Mar 2004 | B1 |
6741000 | Newcomb | May 2004 | B2 |
6781276 | Stiesdal et al. | Aug 2004 | B1 |
6794777 | Fradella | Sep 2004 | B1 |
6794781 | Razzell et al. | Sep 2004 | B2 |
6798082 | Chen | Sep 2004 | B1 |
6800956 | Bartlett | Oct 2004 | B2 |
6814493 | Wobben | Nov 2004 | B2 |
6826874 | Takeuchi et al. | Dec 2004 | B2 |
6833633 | Wobben | Dec 2004 | B2 |
6836028 | Northrup et al. | Dec 2004 | B2 |
6836036 | Dube | Dec 2004 | B2 |
6841892 | Le Nabour et al. | Jan 2005 | B1 |
6844656 | Larsen et al. | Jan 2005 | B1 |
6849965 | Le Nabour et al. | Feb 2005 | B2 |
6853094 | Feddersen et al. | Feb 2005 | B2 |
6856039 | Mikhail et al. | Feb 2005 | B2 |
6876176 | Stefanovi et al. | Apr 2005 | B2 |
6891302 | Gabrys | May 2005 | B1 |
6897577 | Weeber et al. | May 2005 | B2 |
6903466 | Mercier et al. | Jun 2005 | B1 |
6909211 | Ciciliani et al. | Jun 2005 | B2 |
6911741 | Pettersen et al. | Jun 2005 | B2 |
6921243 | Canini et al. | Jul 2005 | B2 |
6929671 | Kim et al. | Aug 2005 | B2 |
6943461 | Kaploun | Sep 2005 | B2 |
6943462 | Wobben | Sep 2005 | B2 |
6943478 | Zepp et al. | Sep 2005 | B2 |
6946750 | Wobben | Sep 2005 | B2 |
6954004 | Skeist et al. | Oct 2005 | B2 |
6984897 | Skeist | Jan 2006 | B2 |
7004724 | Pierce et al. | Feb 2006 | B2 |
7011598 | Flamang et al. | Mar 2006 | B2 |
7019413 | Kinoshita | Mar 2006 | B2 |
7023160 | Virtanen et al. | Apr 2006 | B2 |
7042109 | Gabrys | May 2006 | B2 |
7042110 | Mikhail et al. | May 2006 | B2 |
7042128 | Zepp et al. | May 2006 | B2 |
7045925 | Frager et al. | May 2006 | B2 |
7049719 | Wobben | May 2006 | B2 |
7061133 | Leijon et al. | Jun 2006 | B1 |
7075192 | Bywaters et al. | Jul 2006 | B2 |
7081696 | Ritchey | Jul 2006 | B2 |
7084520 | Zambrano et al. | Aug 2006 | B2 |
7088029 | Hiramatsu | Aug 2006 | B2 |
7098551 | Wobben | Aug 2006 | B2 |
7105941 | Hua | Sep 2006 | B2 |
7105975 | Semones et al. | Sep 2006 | B2 |
7109599 | Watkins | Sep 2006 | B2 |
7109625 | Jore et al. | Sep 2006 | B1 |
7126235 | Bernhoff et al. | Oct 2006 | B2 |
7135952 | Harding | Nov 2006 | B2 |
7145266 | Lynch et al. | Dec 2006 | B2 |
7154191 | Jansen et al. | Dec 2006 | B2 |
7154192 | Jansen et al. | Dec 2006 | B2 |
7154193 | Jansen et al. | Dec 2006 | B2 |
7166984 | Jones et al. | Jan 2007 | B1 |
7170212 | Balson et al. | Jan 2007 | B2 |
7180204 | Grant et al. | Feb 2007 | B2 |
7186083 | Bayly | Mar 2007 | B2 |
7190085 | Moehlenkamp | Mar 2007 | B2 |
7190101 | Hirzel | Mar 2007 | B2 |
7205678 | Casazza et al. | Apr 2007 | B2 |
7215038 | Bacon | May 2007 | B2 |
7230361 | Hirzel | Jun 2007 | B2 |
7231743 | Takeuchi et al. | Jun 2007 | B2 |
7245037 | Ängquist et al. | Jul 2007 | B2 |
7253543 | Akiyama | Aug 2007 | B2 |
7289329 | Chen et al. | Oct 2007 | B2 |
7291956 | Itoh | Nov 2007 | B2 |
7312537 | Walling | Dec 2007 | B1 |
7329099 | Hartman | Feb 2008 | B2 |
7332837 | Ward et al. | Feb 2008 | B2 |
7345377 | Bacon | Mar 2008 | B2 |
7348705 | Cai et al. | Mar 2008 | B2 |
7355309 | Costin et al. | Apr 2008 | B2 |
7358624 | Bacon | Apr 2008 | B2 |
7365472 | Hiramatsu | Apr 2008 | B2 |
7372174 | Jones et al. | May 2008 | B2 |
7375449 | Butterfield | May 2008 | B2 |
7385330 | Trzynadlowski et al. | Jun 2008 | B2 |
7414331 | Datta | Aug 2008 | B2 |
7425771 | Rivas et al. | Sep 2008 | B2 |
7437264 | Pierce et al. | Oct 2008 | B2 |
7439714 | Gonzalez et al. | Oct 2008 | B2 |
7446435 | Zhang et al. | Nov 2008 | B2 |
7468569 | Hirzel | Dec 2008 | B2 |
7478777 | Wobben | Jan 2009 | B2 |
7482720 | Gordon et al. | Jan 2009 | B2 |
7525228 | Chuang et al. | Apr 2009 | B2 |
7538446 | Bonnet | May 2009 | B2 |
7545052 | Gonzalez et al. | Jun 2009 | B2 |
7573173 | Frownfelter | Aug 2009 | B1 |
7592766 | Patel et al. | Sep 2009 | B2 |
7595574 | Ritchey | Sep 2009 | B2 |
7612463 | Cullen et al. | Nov 2009 | B2 |
7633770 | Datta et al. | Dec 2009 | B2 |
7640648 | Rittenhouse | Jan 2010 | B1 |
7646126 | Trzynadlowski et al. | Jan 2010 | B2 |
7646132 | Halstead | Jan 2010 | B2 |
7646178 | Fradella | Jan 2010 | B1 |
7692357 | Qu et al. | Apr 2010 | B2 |
7710081 | Saban et al. | May 2010 | B2 |
7714479 | Seneff et al. | May 2010 | B2 |
7723891 | Rittenhouse | May 2010 | B2 |
7750522 | Gizaw et al. | Jul 2010 | B2 |
7781932 | Jansen | Aug 2010 | B2 |
7808149 | Pabst et al. | Oct 2010 | B2 |
7816833 | Nair | Oct 2010 | B2 |
7821164 | Laskaris et al. | Oct 2010 | B2 |
7830057 | Gieras | Nov 2010 | B2 |
7851965 | Calley et al. | Dec 2010 | B2 |
7852643 | Zhang et al. | Dec 2010 | B2 |
7888839 | Gabrys et al. | Feb 2011 | B2 |
7919879 | Flannery et al. | Apr 2011 | B2 |
7923853 | Lewis | Apr 2011 | B2 |
7923886 | Calley et al. | Apr 2011 | B2 |
7928592 | Wagoner et al. | Apr 2011 | B2 |
7939959 | Wagoner et al. | May 2011 | B2 |
7944068 | Wagoner et al. | May 2011 | B2 |
8097970 | Hyvarinen | Jan 2012 | B2 |
8115348 | Hsu et al. | Feb 2012 | B2 |
8138620 | Wagoner et al. | Mar 2012 | B2 |
8178992 | Meller | May 2012 | B1 |
8217533 | Jones et al. | Jul 2012 | B2 |
8222792 | Platon et al. | Jul 2012 | B2 |
8373307 | Sihler et al. | Feb 2013 | B2 |
8426995 | Langel | Apr 2013 | B2 |
20030020353 | Lopatinsky et al. | Jan 2003 | A1 |
20040021437 | Maslov et al. | Feb 2004 | A1 |
20040027020 | Newcomb | Feb 2004 | A1 |
20040245866 | Lopatinsky et al. | Dec 2004 | A1 |
20050067910 | Okura | Mar 2005 | A1 |
20050120856 | Duford et al. | Jun 2005 | A1 |
20050285470 | Itoh | Dec 2005 | A1 |
20060003604 | Angerpointner | Jan 2006 | A1 |
20060012263 | Smith et al. | Jan 2006 | A1 |
20060028092 | Wang et al. | Feb 2006 | A1 |
20060055265 | Zalusky | Mar 2006 | A1 |
20060202584 | Jore | Sep 2006 | A1 |
20070152536 | Chuang et al. | Jul 2007 | A1 |
20080088200 | Ritchey | Apr 2008 | A1 |
20080100166 | Stahlhut et al. | May 2008 | A1 |
20080100174 | Stahlhut et al. | May 2008 | A1 |
20090295231 | Gaffney et al. | Dec 2009 | A1 |
20110006600 | Fontana et al. | Jan 2011 | A1 |
20110133461 | Hjort | Jun 2011 | A1 |
20110241630 | Ritchey et al. | Oct 2011 | A1 |
20110273048 | Jore et al. | Nov 2011 | A1 |
20120104894 | Van Den Bossche et al. | May 2012 | A1 |
20120155131 | Moreno-Castaneda et al. | Jun 2012 | A1 |
20120175962 | Zhan et al. | Jul 2012 | A1 |
20120200177 | Atkinson et al. | Aug 2012 | A1 |
20120217746 | Groendahl et al. | Aug 2012 | A1 |
20120217831 | Jore et al. | Aug 2012 | A1 |
20120221159 | Olesen | Aug 2012 | A1 |
20120243274 | Feng et al. | Sep 2012 | A1 |
20130015703 | Rouse et al. | Jan 2013 | A1 |
Number | Date | Country |
---|---|---|
665303 | Apr 1988 | CH |
1732011 | Dec 2006 | EP |
59-067860 | Apr 1984 | JP |
S63143077 | Sep 1988 | JP |
10-285894 | Oct 1998 | JP |
WO 2010083054 | Jul 2010 | WO |
Entry |
---|
Chinese Office Action dated Dec. 11, 2015 for Chinese Application No. 201410069149.5. |
Second Chinese Office Action dated Jul. 6, 2016 for Chinese Application No. 201410069149.5. |
Office Action for Chinese Application No. 201080004779.4, mailed Feb. 6, 2013. |
International Search Report and Written Opinion for International Application No. PCT/US2010/000112, mailed Mar. 16, 2010. |
Extended European Search Report Action dated Jan. 9, 2017 for European Application No. 16189324.3. |
Number | Date | Country | |
---|---|---|---|
20140175922 A1 | Jun 2014 | US |
Number | Date | Country | |
---|---|---|---|
61205435 | Jan 2009 | US |
Number | Date | Country | |
---|---|---|---|
Parent | 13144642 | US | |
Child | 14193012 | US |