PLANAR COMPOSITE STRUCTURES AND ASSEMBLIES FOR AXIAL FLUX MOTORS AND GENERATORS

• US 20180138770A1
• Filed: 12/22/2017
• Published: 05/17/2018
• Est. Priority Date: 10/02/2015
• Status: Active Grant

• Current Assignee: E-Circuit Motors
• Original Assignee: E-Circuit Motors
• Inventors: Shaw, Steven Robert
• Granted Patent: US 10,170,953 B2
• Time in Patent Office: Days
• CPC Class Codes: H02K 1/182 to stators axially facing the rotor, i.e. with axial or conical air gap
• CPC Class Codes: H02K 1/27 Rotor cores with permanent magnets
• CPC Class Codes: H02K 21/24 with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• CPC Class Codes: H02K 3/26 consisting of printed conductors
• CPC Class Codes: H02K 3/50 Fastening of winding heads, equalising connectors, or connections thereto
• CPC Class Codes: H05K 1/0298 Multilayer circuits
• CPC Class Codes: H05K 1/165 incorporating printed inductors
• CPC Class Codes: H05K 2201/09227 Layout details of a plurality of traces, e.g. escape layout for Ball Grid Array [BGA] mounting

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.

Claims

1. A planar composite structure (PCS) for use in an axial flux motor or generator, comprising:

a dielectric layer; and

a first conductive layer disposed on the dielectric layer, the first conductive layer comprising first conductive traces that form;

a first portion of a first winding that, when energized, generates magnetic flux for a first phase of the motor or generator, and

a first portion of a second winding that, when energized, generates magnetic flux for a second phase of the motor or generator.

2. The PCS of claim 1, wherein the first conductive traces comprise:

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.

3. The PCS of claim 2, wherein:

the first conductive end turns comprise a first outer end turn and a second outer end turn;

the first outer end turn electrically interconnects portions of a first pair of the first radial conductors at the second radial distance;

the second outer end turn electrically interconnects portions of a second pair of the first radial conductors at the second radial distance; and

the first portion of the first winding comprises the first outer end turn; and

.

the first portion of the second winding comprises the second outer end turn.

4. The PCS of claim 2, wherein:

the first conductive end turns comprise a first inner end turn and a second inner end turn;

the first inner end turn electrically interconnects portions of a first pair of the first radial conductors at the first radial distance;

the second inner end turn electrically interconnects portions of a second pair of the first radial conductors at the first radial distance; and

the first portion of the first winding comprises the first inner end turn; and

.

the first portion of the second winding comprises the second inner end turn.

5. The PCS of claim 4, wherein:

the first winding comprises a second portion electrically connected in series with the first portion of the first winding;

the first conductive end turns further comprise a first outer end turn;

the first outer end turn electrically interconnects a portion of one of the first pair of the first radial conductors at the second radial distance and a portion of another one of the first radial conductors at the second radial distance; and

the second portion of the first winding comprises the first outer end turn.

6. The PCS of claim 5, wherein the first inner end turn and the first outer end turn are arranged so that the first and second portions of the first winding form a serpentine pattern.

7. The PCS of claim 6, wherein:

the first conductive layer is located on a first side of the dielectric layer;

the PCS further comprises a second conductive layer located on a second side of the dielectric layer; and

the second conductive layer comprises second conductive traces that form a third portion of the first winding, wherein the third portion of the first winding is connected in series with the second portion of the first winding.

8. The PCS of claim 7, wherein the second conductive traces comprise:

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 is electrically connected to a corresponding one of the first radial conductors; and

second conductive end turns, each of the second conductive end turns interconnecting a respective pair of the second radial conductors.

9. The PCS of claim 8, wherein:

the second conductive end turns comprise a third inner end turn;

the third inner end turn electrically interconnects portions of a first pair of the second radial conductors at the first radial distance; and

the third portion of the first winding comprises the third inner end turn.

10. The PCS of claim 9, wherein:

the first winding comprise a fourth portion electrically connected in series with the third portion of the first winding;

the first conductive end turns further comprise a second outer end turn;

the second outer end turn electrically interconnects portions of a second pair of the second radial conductors at the second radial distance; and

the fourth portion of the first winding comprises the second outer end turn.

11. The PCS of claim 9, wherein:

the first winding comprise a fourth portion electrically connected in series with the third portion of the first winding;

the second conductive end turns further comprise a second outer end turn;

the second outer end turn electrically interconnects a portion of one of the first pair of the second radial conductors at the second radial distance and a portion of another one of the second radial conductors at the second radial distance; and

the fourth portion of the first winding comprises the second outer end turn.

12. The PCS of claim 8, further comprising:

vias through the dielectric layer, the vias electrically interconnecting each of the second radial conductors with the corresponding one of the first radial conductors.

13. The PCS of claim 1, wherein:

the first winding comprises a first serpentine winding; and

the second winding comprises a second serpentine winding.

14. 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 form a first portion of a winding that, when energized, generates magnetic flux for a first phase of the motor or generator;

a second conductive layer located on a second side of the dielectric layer, the second conductive layer comprising second conductive traces that form a second portion of the winding;

wherein

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.

15. The PCS of claim 14, wherein:

the first conductive traces comprise;

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; and

the second conductive traces comprise;

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 is electrically connected to a corresponding one of the first radial conductors, and

second conductive end turns, each of the second conductive end turns interconnecting a respective pair of the second radial conductors.

16. The PCS of claim 15, wherein:

the first conductive end turns comprise a first inner end turn;

the first inner end turn electrically interconnects portions of a first pair of the first radial conductors at the first radial distance;

the first portion of the winding comprises the first inner end turn;

the second conductive end turns comprise a second inner end turn;

the second inner end turn electrically interconnects portions of a first pair of the second radial conductors at the first radial distance; and

the second portion of the winding comprises the second inner end turn.

17. The PCS of claim 16, wherein:

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;

the first conductive end turns further comprise a first outer end turn;

the first outer end turn electrically interconnects a portion of one of the first pair of the first radial conductors at the second radial distance and a portion of another one of the first radial conductors at the second radial distance; and

the third portion of the winding comprises the first outer end turn.

18. The PCS of claim 17, wherein the first inner end turn, the second inner end turn, and the first outer end turn are arranged so that the first, second, and third portions of the first winding form a serpentine pattern.

19. The PCS of claim 18, wherein:

the winding comprise a fourth portion electrically connected in series with the second portion of the winding;

the first conductive end turns further comprise a second outer end turn;

the second outer end turn electrically interconnects portions of a second pair of the second radial conductors at the second radial distance;

the fourth portion of the winding comprises the second outer end turn.

20. The PCS of claim 18, wherein:

the winding comprise a fourth portion electrically connected in series with the second portion of the winding;

the second conductive end turns further comprise a second outer end turn;

the second outer end turn electrically interconnects a portion of one of the first pair of the second radial conductors at the second radial distance and a portion of another one of the second radial conductors at the second radial distance; and

the fourth portion of the winding comprises the second outer end turn.

21. The PCS of claim 15, further comprising:

vias through the dielectric layer, the vias electrically interconnecting each of the second radial conductors with the corresponding one of the first radial conductors.

22. The PCS of claim 14, wherein:

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, wherein;

the third portion of the winding includes the first portion of the winding, and

the third portion of the winding circumscribes a first region of the first subassembly at least once; and

the second subassembly includes a fourth portion of the winding, wherein;

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.

23. A planar composite structure (PCS) for use in an axial flux motor or generator, comprising:

a 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;

a 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;

a 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;

a 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;

wherein;

the first radial conductors are electrically connected to corresponding ones of the second radial conductors by first blind or buried vias, and

the third radial conductors are electrically connected to corresponding ones of the fourth radial conductors by second blind or buried vias.

24. The PCS of claim 23, wherein:

the first conductive traces further comprises first conductive end turns, each of the first conductive end turns interconnecting a respective pair of the first radial conductors;

the second conductive traces further comprises second conductive end turns, each of the second conductive end turns interconnecting a respective pair of the second radial conductors;

the third conductive traces further comprises third conductive end turns, each of the third conductive end turns interconnecting a respective pair of the third radial conductors; and

the fourth conductive traces further comprises fourth conductive end turns, each of the fourth conductive end turns interconnecting a respective pair of the fourth radial conductors.

25. The PCS of claim 24, wherein:

the first radial conductors, the second radial conductors, the first conductive end turns, and the second conductive end turns establish electrical pathways for a first portion of a winding that, when energized, generates magnetic flux for a first phase of the motor or generator;

the third radial conductors, the fourth radial conductors, the third conductive end turns, and the fourth conductive end turns establish electrical pathways for a second portion of the winding; and

the first portion of the winding is connected in series with the second portion of the winding.

26. 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.

27. The PCS of claim 26, further comprising:

a second subassembly comprising second conductive layers, which are different than the first conductive layers, that include second radial conductors, third end turn conductors, and fourth end turn conductors, wherein;

the third end turn conductors interconnect a first group of the second radial conductors to form a third winding for the first phase of the axial flux motor or generator,

the fourth end turn conductors interconnect a second group of the second radial conductors to form a fourth winding for the second phase of the axial flux motor or generator, and

the first subassembly includes more third end turn conductors than fourth end turn conductors.

28. The PCS of claim 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.

29. The PCS of claim 27, wherein:

a number of the first end turn conductors plus a number of the third end turn conductors is equal to a number the second end turn conductors plus a number of the four end turn conductors.

30. The PCS of claim 26, wherein:

the first end turn conductors comprise first inner end turn conductors and first outer end turn conductors;

the second end turn conductors comprise second inner end turn conductors and second outer end turn conductors;

each of the first inner end turn conductors electrically interconnects portions of a respective pair of the first radial conductors at the first radial distance;

each of the first outer end turn conductors electrically interconnects portions of a respective pair of the first radial conductors at the second radial distance;

each of the second inner end turn conductors electrically interconnects portions of a respective pair of the first radial conductors at the first radial distance;

each of the second outer end turn conductors electrically interconnects portions of a respective pair of the first radial conductors at the second radial distance;

the first subassembly includes a same number of first inner end turn conductors as second inner end turn conductors; and

the first subassembly includes more second outer end turn conductors than first outer end turn conductors.