Structures and methods for thermal management in printed circuit board stators

• US 9,673,684 B2
• Filed: 06/30/2016
• Issued: 06/06/2017
• Est. Priority Date: 10/02/2015
• Status: Active Grant

• Current Assignee: E-Circuit Motors
• Original Assignee: E-Circuit Motors
• Inventors: Shaw, Steven R.
• Primary Examiner(s): DESAI, NAISHADH N
• Application Number:
  US15/199,527
• Publication Number:
  US 20170098982A1
• Time in Patent Office: 341 Days
• Field of Search: 310179-210, 310 52
• CPC Class Codes: H02K 3/26 consisting of printed conductors
• CPC Class Codes: H02K 9/223 Heat bridges

Abstract

A stator for a motor or generator including a planar composite structure (PCS) having at least one dielectric layer and a plurality of conductive layers is provided. The stator includes first conductive elements extending radially to a distance r₁ from a center of, and disposed angularly on, the PCS. Each first conductive element includes a preferred termination structure to connect with at least one of a plurality of second conductive elements extending radially from a radius r₂ from the center of, and disposed angularly on, the PCS.

Claims

1. A component for use in a motor or generator, comprising:

a planar composite structure (PCS) comprising at least one dielectric layer and a plurality of conductive layers;

a plurality of first conductive elements disposed on the conductive layers of the PCS and interconnected to form windings that link flux and carry current in an active area of the component, wherein, on at least one conductive layer of the PCS, the windings are disposed within one or more winding regions each having a periphery defined by an outermost winding on the at least one conductive layer; and

at least one second conductive element disposed on the at least one conductive layer of the PCS outside each of the one or more winding areas on the at least one conductive layer, the at least one second conductive element having a beginning point thermally connected to at least one of the windings and an ending point to which heat from the at least one of the windings can be communicated so as to conduct heat away from the active area of the component;

wherein the at least one second conductive element is configured and arranged on the PCS so that a current density integrated over a cross-section of the at least one second conductive element between the beginning point and the ending point would be zero if the windings were excited with a direct current.

2. The stator of claim 1, wherein:

the PCS is characterized at least in part by a center origin point and a periphery;

the plurality of first conductive elements extend radially to a distance r₁ from the center origin point toward the periphery of the PCS and are disposed angularly on the PCS; and

the at least one second conductive element comprises a plurality of second conductive elements that extend radially from a radius r₂ from the center origin point toward the periphery of the PCS and are disposed angularly on the PCS.

3. The stator of claim 2, wherein r₁=r₂.

4. The stator of claim 2, wherein r₁<

r₂.

5. The stator of claim 1, wherein:

at least one of the plurality of first conductive elements is terminated in a preferred termination structure; and

the at least one of the plurality of first conductive elements is connected to the at least one second conductive element at the preferred termination structure according to a connection configuration.

6. The stator of claim 5, wherein the preferred termination structure includes a hammerhead configuration.

7. The stator of claim 5, wherein the connection configuration comprises a thermal connection.

8. The stator of claim 5, wherein the connection configuration comprises an electrical connection.

9. The stator of claim 1, wherein at least one of the plurality of first conductive elements and the at least one second conductive element are located on different conductive layers of the PCS.

10. The stator of claim 7, wherein the at least one of the plurality of first conductive elements and the at least one second conductive element are located on different conductive layers of the PCS.

11. The stator of claim 10, wherein:

the PCS is characterized at least in part by a center origin point and a periphery;

the plurality of first conductive elements extend radially to a distance r₁ from the center origin point toward the periphery of the PCS and are disposed angularly on the PCS;

the at least one second conductive element comprises a plurality of second conductive elements that extend radially from a radius r₂ from the center origin point toward the periphery of the PCS and are disposed angularly on the PCS;

the thermal connection comprises a plurality of third conductive elements extending radially from a radius r₃ from the center origin point toward the periphery of the PCS and disposed angularly on the PCS; and

at least one of the third conductive elements and the at least one second conductive element are coincident and located on different conductive layers.

12. The stator of claim 11, wherein r₂<

r₃.

13. The stator of claim 8, wherein the at least one of the plurality of first conductive elements and the at least one second conductive element are located on different conductive layers of the PCS.

14. The stator of claim 13, wherein the electrical connection comprises at least one via originating on one of the conductive layers and terminating on another of the conductive layers.

15. The stator of claim 1, wherein:

the PCS is characterized at least in part by a center origin point and a periphery;

the plurality of first conductive elements extend radially from a starting radius r₀ from the center origin point toward the periphery of the PCS and are disposed angularly on the PCS; and

the at least one second conductive element comprises a plurality of second conductive elements that extend radially from a radius r<sub>−

1</sub> from the center origin point toward the center origin point of the PCS and are disposed angularly on the PCS.

16. The stator of claim 15, wherein r₋

1<

r₀.

17. The stator of claim 15, wherein r₋

1=r₀.

18. The stator of claim 15, wherein:

at least one of the plurality of first conductive elements originates in a preferred starting structure; and

the at least one of the plurality of first conductive elements is connected to the at least one second conductive element at the preferred starting structure according to a connection configuration.

19. The stator of claim 18, wherein the preferred starting structure includes a radial via block configuration.

20. The stator of claim 18, wherein the connection configuration comprises a thermal connection.

21. The stator of claim 18, wherein the connection configuration comprises an electrical connection.

22. The stator of claim 15, wherein at least one of the plurality of first conductive elements and the at least one second conductive element are located on different conductive layers of the PCS.

23. The stator of claim 20, wherein the at least one of the plurality of first conductive elements and the at least one second conductive element are located on different conductive layers of the PCS.

24. The stator of claim 23, wherein:

the thermal connection comprises a plurality of third conductive elements extending radially from a radius r<sub>−

2</sub> from the center origin point toward the center origin point of the PCS and disposed angularly on the PCS; and

at least one of the third conductive elements and the at least one second conductive element are coincident and located on different conductive layers.

25. The stator of claim 24, wherein r₋

2<

r<sub>−

1</sub>.

26. The stator of claim 21, wherein the at least one of the plurality of first conductive elements and the at least one second conductive element are located on different conductive layers of the PCS.

27. The stator of claim 26, wherein the electrical connection comprises at least one via originating on one of the conductive layers and terminating on another of the conductive layers.