Planar composite structures and assemblies for axial flux motors and generators
First Claim
1. A planar composite structure (PCS) for use in an axial flux motor or generator, comprising:
- a dielectric layer;
a first conductive layer disposed on a first side of the dielectric layer, the first conductive layer comprising first conductive traces that include;
first radial conductors, each of the first radial conductors extending radially at least between a first radial distance and a second radial distance that is greater than the first radial distance, andfirst conductive end turns, each of the first conductive end turns interconnecting a respective pair of the first radial conductors, the first conductive end turns including a first inner end turn and a second inner end turn, the first inner end turn electrically interconnecting portions of a first pair of the first radial conductors at the first radial distance, and the second inner end turn electrically interconnecting portions of a second pair of the first radial conductors at the first radial distance;
wherein the first conductive traces form;
a first portion of a first winding that, when energized, generates magnetic flux for a first phase of the motor or generator, the first portion of the first winding including the first inner end turn, anda first portion of a second winding that, when energized, generates magnetic flux for a second phase of the motor or generator, the first portion of the second winding including the second inner end turn;
a second conductive layer located on a second side of the dielectric layer, the second conductive layer comprising second conductive traces that include second radial conductors, wherein each of the second radial conductors extends radially at least between the first radial distance and the second radial distance; and
vias through the dielectric layer, each of the first radial conductors being electrically connected through at least one respective via to a corresponding one of the second radial conductors.
1 Assignment
0 Petitions
Accused Products
Abstract
A planar composite structure (PCS) for use in an axial flux motor or generator may include a conductive layer disposed on a dielectric layer, with the conductive layer comprising conductive traces that form portions of at least two windings that, when energized, generate magnetic flux for at least two corresponding phases of the motor or generator. A PCS may additionally or alternatively include a first conductive layer comprising first conductive traces that form a first portion of a winding that, when energized, generates magnetic flux for a first phase of the motor or generator, and a second conductive layer, which is different than the at least one first conductive layer, comprising second conductive traces that form a second portion of the winding. The first portion of the winding may be connected in series with the second portion of the winding, and the first and second portions of the winding may be configured and arranged such that a same amount of current flows through each of the first and second portions of the winding.
110 Citations
30 Claims
-
1. A planar composite structure (PCS) for use in an axial flux motor or generator, comprising:
-
a dielectric layer; a first conductive layer disposed on a first side of the dielectric layer, the first conductive layer comprising first conductive traces that include; first radial conductors, each of the first radial conductors extending radially at least between a first radial distance and a second radial distance that is greater than the first radial distance, and first conductive end turns, each of the first conductive end turns interconnecting a respective pair of the first radial conductors, the first conductive end turns including a first inner end turn and a second inner end turn, the first inner end turn electrically interconnecting portions of a first pair of the first radial conductors at the first radial distance, and the second inner end turn electrically interconnecting portions of a second pair of the first radial conductors at the first radial distance; wherein the first conductive traces form; a first portion of a first winding that, when energized, generates magnetic flux for a first phase of the motor or generator, the first portion of the first winding including the first inner end turn, and a first portion of a second winding that, when energized, generates magnetic flux for a second phase of the motor or generator, the first portion of the second winding including the second inner end turn; a second conductive layer located on a second side of the dielectric layer, the second conductive layer comprising second conductive traces that include second radial conductors, wherein each of the second radial conductors extends radially at least between the first radial distance and the second radial distance; and vias through the dielectric layer, each of the first radial conductors being electrically connected through at least one respective via to a corresponding one of the second radial conductors. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 22, 23, 24, 25, 26, 28, 29)
-
-
9. A planar composite structure (PCS) for use in an axial flux motor or generator, comprising:
-
a dielectric layer; a first conductive layer located on a first side of the dielectric layer, the first conductive layer comprising first conductive traces that include; first radial conductors, each of the first radial conductors extending radially at least between a first radial distance and a second radial distance that is greater than the first radial distance, and first conductive end turns, each of the first conductive end turns interconnecting a respective pair of the first radial conductors; a second conductive layer located on a second side of the dielectric layer, the second conductive layer comprising second conductive traces that include; second radial conductors, wherein each of the second radial conductors extends radially at least between the first radial distance and the second radial distance, and second conductive end turns, each of the second conductive end turns interconnecting a respective pair of the second radial conductors; and vias through the dielectric layer, each of the first radial conductors being electrically connected through at least one respective via to a corresponding one of the second radial conductors;
wherein;the first conductive traces form a first portion of a winding that, when energized, generates magnetic flux for a first phase of the motor or generator, the second conductive traces form a second portion of the winding, the first portion of the winding is connected in series with the second portion of the winding, and the first and second portions of the winding are configured and arranged such that a same amount of current flows through each of the first and second portions of the winding. - View Dependent Claims (10, 11, 12, 13, 27, 30)
-
-
14. A planar composite structure (PCS) for use in an axial flux motor or generator, comprising:
-
a first dielectric layer; a first subassembly located on a first side of the first dielectric layer, the first subassembly including; a second dielectric layer, a first conductive layer located on a first side of the second dielectric layer, the first conductive layer comprising first conductive traces that form a first portion of a winding that, when energized, generates magnetic flux for a first phase of the motor or generator, wherein the first conductive traces include; first radial conductors, each of the first radial conductors extending radially at least between a first radial distance and a second radial distance that is greater than the first radial distance, and first conductive end turns, each of the first conductive end turns interconnecting a respective pair of the first radial conductors, a second conductive layer located on a second side of the second dielectric layer, the second conductive layer comprising second conductive traces that include second radial conductors, each of the second radial conductors extending radially at least between the first radial distance and the second radial distance, and first vias through the second dielectric layer, each of the first radial conductors being electrically connected through at least one respective first via to a corresponding one of the second radial conductors; and a second subassembly located on a second side of the first dielectric layer, the second subassembly including; a third dielectric layer, a third conductive layer located on a first side of the third dielectric layer, the third conductive layer comprising third conductive traces that form a second portion of the winding, wherein the third conductive traces include; third radial conductors, each of the third radial conductors extending radially at least between the first radial distance and the second radial distance, and second conductive end turns, each of the second conductive end turns interconnecting a respective pair of the third radial conductors, and a fourth conductive layer located on a second side of the third dielectric layer, the fourth conductive layer comprising fourth conductive traces that include fourth radial conductors, each of the fourth radial conductors extending radially at least between the first radial distance and the second radial distance, and second vias through the third dielectric layer, each of the third radial conductors being electrically connected through at least one respective second via to a corresponding one of the fourth radial conductors, wherein; the first portion of the winding is connected in series with the second portion of the winding, the first and second portions of the winding are configured and arranged such that a same amount of current flows through each of the first and second portions of the winding, the first subassembly further 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 circumscribes a first region of the first subassembly at least once, the second subassembly further includes a fourth portion of the winding, the fourth portion of the winding includes the second portion of the winding, and the fourth portion of the winding circumscribes a second region of the second subassembly at least once.
-
-
15. A planar composite structure (PCS) for use in an axial flux motor or generator, comprising:
-
a first dielectric layer; a first conductive layer on a first side of the first dielectric layer, the first conductive layer comprising first conductive traces, the first conductive traces including; first radial conductors that extend radially from a first radial distance to a second radial distance that is greater than the first radial distance, and first conductive end turns, each of the first conductive end turns interconnecting a respective pair of the first radial conductors; a second conductive layer on a second side of the first dielectric layer, the second conductive layer comprising second conductive traces, the second conductive traces including; second radial conductors that extend radially from the first radial distance to the second radial distance, and second conductive end turns, each of the second conductive end turns interconnecting a respective pair of the second radial conductors; first blind or buried vias through the first dielectric layer, each of the first radial conductors being electrically connected through at least one respective first via to a corresponding one of the second radial conductors; a second dielectric layer; a third conductive layer on a first side of the second dielectric layer, the third conductive layer comprising third conductive traces, the third conductive traces including; third radial conductors that extend radially from the first radial distance to the second radial distance, and third conductive end turns, each of the third conductive end turns interconnecting a respective pair of the third radial conductors; a fourth conductive layer on a second side of the second dielectric layer, the fourth conductive layer comprising fourth conductive traces, the fourth conductive traces including; fourth radial conductors that extend radially from the first radial distance to the second radial distance, and fourth conductive end turns, each of the fourth conductive end turns interconnecting a respective pair of the fourth radial conductors; second blind or buried vias through the second dielectric layer, each of the third radial conductors being electrically connected through at least one respective second via to a corresponding one of the fourth radial conductors; and a third dielectric layer between the second conductive layer and the third conductive layer. - View Dependent Claims (16)
-
-
17. A planar composite structure (PCS) for use in axial flux motor or generator, comprising:
a first subassembly comprising first conductive layers that include first radial conductors that extend radially from a first radial distance to a second radial distance that is greater than the first radial distance, first end turn conductors, and second end turn conductors, wherein; the first end turn conductors interconnect 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 conductors interconnect a second group of the first radial conductors to form a second winding for a second phase of the axial flux motor or generator, and the first subassembly includes more second end turn conductors than first end turn conductors. - View Dependent Claims (18, 19, 20, 21)
Specification