Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K3/00—Details of windings
  • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
  • H02K3/26—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors consisting of printed conductors
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K21/00—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
  • H02K21/12—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets
  • H02K21/24—Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets axially facing the armatures, e.g. hub-type cycle dynamos
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K3/00—Details of windings
  • H02K3/46—Fastening of windings on the stator or rotor structure
  • H02K3/47—Air-gap windings, i.e. iron-free windings

Definitions

• PCS planar composite structure
• 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 comprises 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, as well as a first portion of a second winding that, when energized, generates magnetic flux for a second phase of the motor or generator.
• 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, and a second conductive layer located on a second side of the dielectric layer.
• the first conductive layer comprise 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.
• the second conductive layer comprises second conductive traces that 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 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.
• a planar composite structure (PCS) for use in an axial flux motor or generator comprises a first conductive layer comprising first conductive traces, a second conductive layer comprising second conductive traces, a third conductive layer comprising third conductive traces, and a fourth conductive layer comprising fourth conductive traces.
• the first conductive traces 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, the second conductive traces include second radial conductors that extend radially from the first radial distance to the second radial distance, the third conductive traces including third radial conductors that extend radially from the first radial distance to the second radial distance, and the fourth conductive traces including fourth radial conductors that extend radially from the first radial distance to the second radial distance.
• the first radial conductors are electrically connected to corresponding ones of the second radial conductors by first blind or buried vias
• the third radial conductors are electrically connected to corresponding ones of the fourth radial conductors by second blind or buried vias.
• a planar composite structure (PCS) for use in axial flux motor or generator comprises a 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.
• 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.
• the first subassembly includes more second end turn conductors than first end turn conductors.
• FIG. 1 A illustrates a "turns layer" of a planar stator having a winding layout like that described in U.S. Pat. No. 7,109,625 ("the '625 patent”);
• FIG. IB illustrates a "link layer" of a planar stator having a winding layout like that described in the '625 patent
• FIG. 1C illustrates the link layer shown in FIG. IB on top of the turns layer shown in FIG. 1 A, with hidden lines removed;
• FIG. 2 shows a selected view of a portion of a stator configuration having a stack of three six-layer subassemblies
• FIG. 3 shows radial traces at a single angular position, across twelve conductive layers of a PCS, organized in three parallel groups connected by blind or buried vias;
• FIG. 4 shows inner end turns of the type described in the '625 patent, which are similar to the inner end turns shown in FIG. 1 A;
• FIGS. 5 A and 5B show an alternative arrangement of inner end turns on two respective conductive layers of a PCS
• FIG. 6 shows outer end turns of the type described in the '625 patent, which are similar to the outer end turns shown in FIG. 1 A;
• FIGS. 7A and 7B show an alternative arrangement of outer end turns on two respective conductive layers of a PCS
• FIG. 8 shows inner end turns and outer end turns that interconnect radial traces to form a single coil of a stator in accordance with the winding layout taught by the '625 patent;
• FIG. 9 shows an alternate arrangement of inner and outer end turns for a single phase in a plan view of multiple layers
• FIG. 10A shows an expanded (in the z-axis) perspective view of a subassembly including four conductive layers, with inner end turns and outer end turns corresponding to a selected phase for clarity;
• FIG. 10B illustrates the positions of inner end turns and outer end turns for a first phase within the subassembly shown in FIG. 10A;
• FIG. 11 A illustrates the positions of inner end turns and outer end turns for a second phase within the subassembly shown in FIG. 10A;
• FIG. 1 IB illustrates the positions of inner end turns and outer end turns for a third phase within the subassembly shown in FIG. 10A.
• FIG. 12A shows an expanded (in the z-axis) perspective view of an assembly of three subassemblies, each similar to the subassembly shown in FIG. 10A;
• FIG. 12B illustrates the positions of inner end turns and outer end turns for a first phase within the stack of three subassemblies shown in FIG. 12 A;
• FIG. 13 A illustrates the positions of inner end turns and outer end turns for a second phase within the stack of three subassemblies shown in FIG. 12 A;
• FIG. 13B illustrates the positions of inner end turns and outer end turns for a third phase within the stack of three subassemblies shown in FIG. 12 A;
• FIG. 14 shows an expanded (in the z-axis) perspective view an example embodiment of a stator that employs serpentine windings like that shown in FIG. 9, and in which inner end turns of the type shown in FIGS. 5 A and B and outer end turns of the type shown in FIGS. 7 A and 7B are employed to establish all of the winding connections needed for three phases in an assembly that includes just two conductive layers;
• FIG. 15A shows an expanded (in the z-axis) perspective view of only the portions of the assembly shown in FIG. 14 that correspond to a first phase of the stator;
• FIG. 15B show the portions of the upper conductive layer shown in FIG. 15A that contribute to the windings for the first phase
• FIG. 15C shows the portions of the lower conductive layer shown in FIG. 15A that contribute to the windings for the first phase;
• FIG. 16A illustrates how the windings for a second phase can make their way through the assembly shown in FIG. 14, with the portions of the assembly corresponding to the other two phases removed for illustration purposes;
• FIG. 16B illustrates how the windings for a third phase can make their way through the assembly shown in FIG. 14, with the portions of the assembly corresponding to the other two phases removed for illustration purposes;
• FIGS. 17A and 17B illustrate an example of a process for forming a multi-layer PCS assembly/subassembly
• FIGS. 18A illustrates a system in which a PCS like those described herein is employed as a stator in an axial flux motor or generator;
• FIG. 18B illustrates an expanded view of the system shown in FIG. 18 A.
• a planar composite structure that may be used, for example, as a stator in an axial flux motor or generator, can be constructed by forming multiple layers of conductive traces (conductive layers) on one or more layers of non-conductive, dielectric material (dielectric layers) Examples of stators of this type are described in U.S. Patent No. 7,109,625 ("the '625 patent"), U.S. Patent No. 9,673,688, U.S. Patent No. 9,673,684, and U.S. Patent No. 9,800,109, the entire contents of each of which is incorporated herein by reference.
• FIGS. 1 A-C show plan views of two conductive layers of a planar stator having a winding layout like that described in the '625 patent. Together, the layers shown establish the inner and outer "end turns" needed for a single phase.
• FIG. 1 A shows a single "turns layer" LI with inner end turns 102a and outer end turns 106 that arrange the radial traces 104 in coils that are each associated with a pole pair.
• this sixteen-pole stator there are eight such coils. In the example shown, the coils spiral in, such that the end-point of each coil cannot be routed to the beginning point of a subsequent coil on the same layer. This routing difficulty is described in more detail below in connection with FIG. 8.
• FIG. 8 shows a single "turns layer” LI with inner end turns 102a and outer end turns 106 that arrange the radial traces 104 in coils that are each associated with a pole pair.
• the sixteen-pole stator there are eight such coils.
• the coils spiral in,
• IB shows a "link layer" L2, which includes links 108 that serve to connect subsequent coils without interference with the turns layer LI .
• Each of the radial traces 104 on the layer LI is connected to a corresponding (and parallel) radial trace 104 on the layer L2, e.g., using vias (not shown).
• the link layer L2 also includes inner end turns 102b which are redundant with inner end turns 102a in the turns layer LI .
• FIG. 1C shows the link layer L2 on top of the turns layer LI, with hidden lines removed. As seen, in this configuration, the outer end turns 106 and links 108 occupy some of the same space on the outer radius of the stator.
• a complete stator of three phases having a winding layout like that taught by the '625 patent requires a minimum of six conductive layers (i.e., three phases times two layers per phase).
• a balanced stator employing such a winding layout thus requires a multiple of six conductive layers.
• a "balanced stator” refers to a stator in which the electrical load characteristics (in motor mode) or electrical source characteristics (in generator mode) of each phase are equal up to an electrical phase angle.
• FIGS. 1 A-C it should be appreciated that certain details of the depicted design, e.g., particular structures and/or configurations for thermal management and loss reduction, such as those disclosed in U.S. Patent Nos. 9,673,684 and 9,800, 109, are not disclosed in the '625 patent.
• FIGS. 1 A-C thus illustrate only the relative positions of radial traces, inner end turns, outer end turns, and links as taught by the '625 patent, and not the particular structures or configurations the '625 patent discloses for those elements.
• Stators have been designed in which multiple three-phase, balanced stator subassemblies (having six conductive layers each) have been stacked on the same planar composite structure (PCS) and connected in parallel. Such designs may, for example, increase the current capacity and efficiency of the respective phases of the stator, because the current for each phase can be carried along parallel paths within the respective subassemblies.
• FIG. 2 shows a selected view of a portion of a stator configuration having three six-layer subassemblies stacked in this manner, focusing on a single radial trace 204 as it is connected in parallel across eighteen conductive layers (using vias 210).
• FIG. 3 shows a structure analogous to FIG. 2 but related to this disclosure.
• FIG. 3 shows radial traces 304 at a single angular position, across twelve conductive layers of a PCS.
• radial traces 304 are organized in three parallel groups 312a, 312b, 312c connected by blind or buried vias 310. For reasons of manufacture, it is most convenient for each of these groups to have a multiple of two conductive layers. Unlike a stator constructed according to the '625 patent, the respective parallel groups 312a, 312b, 312c of radial traces 304 can be connected in series, thus enabling a higher turns count for each coil of the stator.
• the turns count for the structure shown in FIG. 3, comprising three groups of parallel-connected radial traces, may, for example, be three times higher than the turns count for the structure shown in FIG. 2.
• An example of a stator implementation in which multiple parallel-connected groups of radial traces are connected in series in such a manner is described below in connection with 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. 1 A. These inner end turns 402, together with outer end turns 606 (shown in FIG. 6), form all the connections between respective radial traces 404 that are needed to establish three-turns per pole pair of a single phase.
• one conductive layer including inner end turns 402 like those shown in FIG. 4 and outer end turns 606 like those shown in FIG. 6 (described below) is needed to connect a single phase.
• a minimum of three such conductive layers are needed.
• FIGS. 5 A and 5B show an alternative arrangement of inner end turns 502 on two respective conductive layers L3, L4.
• layer numbers used herein, e.g., "L3,” are provided only to allow identification of the various layers being described and are not intended to imply an order in which various layers are positioned.
• radial traces 404 on layer L3 are connected in parallel with the corresponding (and parallel) radial traces 404 on layer L4, e.g., using vias (not shown in FIGS. 5A and 5B) similar to the vias 310 shown in FIG. 3, inner end turn connections for all of the radial traces 404 shown in FIGS. 5 A and 5B can be established on just two conductive layers.
• such an arrangement allows inner end turns 502 for multiple phases to be provided on the same conductive layer and also allows inner end turns 502 for the same phase to be distributed amongst multiple conductive layers. This is in contrast to the configuration of FIG. 4, where 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.
• either or both of layers L3 and L4 may additionally include outer end turns, which may, for example, be arranged similar to the outer end turns 606 illustrated in FIG. 6 (described below).
• outer end turns may, for example, be arranged similar to the outer end turns 606 illustrated in FIG. 6 (described below).
• Example embodiments of this type are described below in connection with FIGS. 10A, 10B, 11 A, 11B, 12A, 12B, 13A, and 13B.
• outer end turns provided on layers L3 and L4 may be the same or similar to the outer end turns 706 described below in connection with FIGS. 7A and 7B.
• An example embodiment of the latter type is described below in connection with FIGS 14, 15 A, 15B, 15C, 16A, and 16B.
• Other configurations of outer end turns on either or both of layers L3 and L4, or even configurations in which all outer end turns are included on layers other than layers L3 and L4, are also possible and contemplated.
• FIGS. 5A and 5B 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 being depicted on layer L3 in FIG. 5A and a second set of inner end turns 502g, 502h, 502i, 502j, 502k, 5021 being depicted on layer L4 in FIG. 5B.
• a first phase can be supported by inner end turns 502a and 502d on layer L3 in FIG. 5A and inner end turns 502h and 502k on layer L4 in FIG. 5B
• a second phase can be supported by inner end turns 502b and 502e on layer L3 in FIG. 5A and inner end turns 502i and 5021 on layer L4 in FIG.
• a third phase can be supported by inner end turns 502c and 502f on layer L3 in FIG. 5A and inner end turns 502g and 502j on layer L4 in FIG. 5B.
• the inner end turns 502 for each phase consume one-third of layer L3 and one-third of layer L4
• the inner end turns 502 for each phase consume a total of two-thirds of a layer worth of real estate on the layers L3 and L4.
• two conductive layers minimum are needed to form complete inner end turn connections for all three phases, and the conductive layer count should be a multiple of two in order for the stator to be balanced with respect to the inner end turns.
• each phase of a three-phase stator employing such a configuration should preferably have four poles.
• the following equation is preferably satisfied for a three phase stator (where "k" is an integer):
• FIG. 6 shows outer end turns 606 of the type described in the '625 patent, which are similar to the outer end turns 106 shown in FIG. 1 A. These outer end turns 606, together with inner end turns 402 (shown in FIG. 4), form all the connections between respective radial traces 404 that are needed to establish three-turns per pole pair of a single phase.
• one layer including both outer end turns 606 like those shown in FIG. 6 and inner end turns 402 like those shown in FIG. 4 is needed to connect a single phase.
• a minimum of three such conductive layers are needed.
• FIGS. 7A and 7B show an alternative arrangement of outer end turns 706 on two respective conductive layers L5, L6.
• radial traces 404 on layer L5 are connected in parallel with the corresponding (and parallel) radial traces 404 on layer L6, e.g., using vias (not shown in FIGS. 7A and 7B) similar to the vias 310 shown in FIG. 3, outer end turn connections for all of the radial traces 404 shown in FIGS. 7A and 7B can be established on just two layers.
• either or both of layers L5 and L6 may additionally include inner end turns, which may, for example, be arranged similar to the inner end turns 402 illustrated in FIG. 4.
• inner end turns provided on layers L5 and L6 may be the same or similar to the inner end turns 502 described above in connection with FIGS. 5A and 5B.
• An example embodiment of the latter type is described below in connection with FIGS. 14, 15A, 15B, 15C, 16A, and 16B.
• Other configurations of inner end turns on either or both of layers L5 and L6, or even configurations in which all inner end turns are included on layers other than layers L5 and L6, are also possible and contemplated.
• current may additionally or alternatively be fed to respective phases from the inner region of the stator, with one or more inner end turn groups 402, 502 like those shown in FIGS. 4 and 5 being configured differently than the other inner end turn groups to allow for inputs similar to inputs 708a, 708b, and/or 708c, but instead being located in the inner region of the stator.
• a rotor may instead run "outside" the stator, e.g., an annular or tubular rotor structure could surround and rotate about the stator. Such an implementation may make sense, for example, in an embodiment in which current is fed to respective phases from the inner region of the stator.
• FIGS. 7 A and 7B Two complementary sets of outer end turns 706 are shown in FIGS. 7 A and 7B, with a first set of outer end turns 702a, 702b, 702c, 702d, 702e, and 702f being depicted on layer L5 in FIG. 7 A and a second set of outer end turns 702g, 702h, 702i, 702j, 702k, 7021 being depicted on layer L6 in FIG. 7B.
• outer end turns 706 for multiple phases can be provided on the same conductive layer and that outer end turns 706 for a given phase can be distributed amongst multiple conductive layers, it is evident that all the outer end turn connections required for a three-phase stator can be achieved in just the two layers L5 and L6 illustrated.
• a first phase can be supported by outer end turns 706a and 706d on layer L5 in FIG. 7A and outer end turns 706h and 706k on layer L6 in FIG. 7B
• a second phase can be supported by outer end turns 706b and 706e on layer L5 in FIG. 7A and outer end turns 706i and 7061 on layer L6 in FIG.
• a third phase can be supported by outer end turns 706c and 706f on layer L5 in FIG. 7A and outer end turns 706g and 706j on layer L6 in FIG. 7B.
• the outer end turns 706 for each phase consume one-third of layer L5 and one-third of layer L6, the outer end turns 706 for each phase consume a total of two-thirds of a layer worth of real estate on the layers L5 and L6.
• two conductive layers minimum are needed to form complete outer end turn connections for all three phases, and the conductive layer count should be a multiple of two in order for the stator to be balanced with respect to the outer end turns.
• FIG. 8 shows inner end turns 802 and outer end turns 806 that interconnect radial traces 804 to form a single coil of a stator in accordance with the winding layout taught by the '625 patent.
• the coil illustrated can be seen to either begin at a point 808 and spiral "in” to the point 810, or begin at the point 810 and spiral “out” to the point 808.
• the "missing" outer end turn 806 cannot be routed on the same layer as the other turns, because it needs to establish a connection from the inside of the spiral (e.g., point 810) to the outside of the next spiral, or vice versa. As this type of connection proceeds around the stator, it encircles the center point of the stator only once.
• FIG. 9 shows an alternate arrangement of inner and outer end turns for a single phase in a plan view of multiple conductive layers. Three turns are effected in the layers shown.
• inner end turns 502 like 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.
• the inner end turns illustrated in FIG. 9 may include two groups of inner end turns 502 from one layer (e.g., inner end turns 502b and 502e on layer L3 shown in FIG. 5A) and two groups of inner end turns 502 from another layer (e.g., inner end turns 502i and 5021 on layer L4 shown in FIG. 5B).
• inner end turns 502 from two or more conductive layers can enable the formation of a complete set of inner end turn connections for a single phase.
• some or all of the inner end turns illustrated in FIG. 9 may be of the type shown in FIG. 4, i.e., like inner end turns 402, and may be disposed in a common conductive layer.
• some or all of the outer end turns shown in FIG. 9 may be of the type shown in FIG. 6, i.e., like outer end turns 606, and may be disposed in a common conductive layer.
• some or all of the outer end turns illustrated may be of the type shown in FIG. 7, i.e., like outer end turns 706, and may be distributed across two (or more) conductive layers.
• the outer end turns illustrated in FIG. 9 may include two groups of outer end turns 706 from one conductive layer (e.g., outer end turns 706a and 706d on layer L5 shown in FIG.
• outer end turns 706 from another conductive layer (e.g., outer end turns 706h and 706k on layer L6 shown in FIG. 7B).
• outer end turns 706h and 706k on layer L6 shown in FIG. 7B can enable the formation of a complete set of outer end turn connections for a single phase.
• FIGS. 10A, 10B, 11 A, 11B, 12A, 12B, 13A, and 13B illustrate example embodiments of stators that employ serpentine windings like that shown in FIG. 9, and in which inner end turns 502 of the type shown in FIGS. 5A and B and outer end turns 606 of the type shown in FIG. 6 are employed to establish winding connections for one or more subassemblies that each includes four conductive layers. Features of a single such subassembly SI is illustrated in FIGS.
• FIGS. 12A, 12B, 13A, and 13B features a stacked set of three such subassemblies SI, S2, and S3 are illustrated in FIGS. 12A, 12B, 13A, and 13B.
• each of the radial connectors 404 on a given conductive layer of that subassembly is connected to corresponding (and parallel) ones of the radial connectors 404 in the other conductive layers of that same subassembly using vias 310, in the manner illustrated in FIG. 3.
• An illustrative technique for forming multi-layer PCS assemblies/subassemblies like those shown is described below in connection with FIGS. 17A and 17B.
• FIG. 10A shows an expanded (in the z-axis) perspective view of a subassembly SI having four conductive layers, with inner end turns 502b, 502e, 502i, 5021 and outer end turns 606 corresponding to a selected phase for clarity.
• the positions of additional inner end turns 502 and outer end turns 606 that can be incorporated into the structure of FIG. 10A to establish the other two phases of a three phase stator are illustrated in FIGS. 11 A-l IB below.
• FIG. 10B is similar to FIG. 10A but, for illustration purposes, has further portions of the subassembly SI corresponding to the other two phases removed.
• FIG. 10B thus illustrates how the windings for a single phase of a three phase stator can make their way through a subassembly SI having four conductive layers.
• FIGS. 11 A-l IB illustrate how the windings of the two remaining phases may work their way through the subassembly SI shown in FIG. 10A, with the portions of the subassembly corresponding to the other two phases removed for illustration purposes.
• FIG. 10B illustrates the positions of inner end turns 502b, 502e, 502i, 5021 and outer end turns 606 for a first phase within the subassembly SI
• FIG. 11 A illustrates the positions of inner end turns 502a, 502d, 502h, 502k and outer end turns 606 for a second phase within the subassembly SI
• FIG. 1 IB illustrates the positions of inner end turns 502c, 502f, 502g, 502i and outer end turns 606 for a third phase within the subassembly SI .
• 10A and 10B appear with multiplicity two over four conductive layers, with the inner end turns 502b and 502e appearing on two of the four illustrated layers and inner end turns 502i and 5021 appearing on remaining two layers.
• the inner end turns 502c, 502f, 502g, 502i appear with multiplicity two over the four layers, with the inner end turns 502c and 502f appearing on two of the four illustrated layers and inner end turns 502g and 502i appearing on remaining two layers. Accordingly, for all three phases of the subassembly SI shown in FIGS. 10A, 10B, 11 A and 1 IB, the inner end turns 502 appear with multiplicity two over four conductive layers and are balanced (equal for each phase) because the subassembly SI has a multiple of two conductive layers.
• the outer end turns 606 also appear with multiplicity two over the four layers illustrated.
• the outer end turns 606 occupy two of four conductive layers.
• the outer end turns 606 for the other two phases are on the other two conductive layers, but without redundancy. That is, the outer end turns 606 for the second phase (shown in FIG. 11 A) appear on only a single conductive layer, as do the outer end turns 606 for the third phase (shown in FIG. 1 IB).
• the subassembly SI shown in FIGS. 10A, 10B, 11 A and 1 IB has all the connections required of a three-phase stator, but is unbalanced because of the unequal redundancy of outer end turns 606 over the phases.
• FIG. 12A shows an expanded (in the z-axis) perspective view of an assembly of three subassemblies SI, S2, and S3, each similar to the subassembly shown in FIG. 10A.
• two or more such respective subassemblies may be laminated together to form a single PCS.
• FIG. 12A shows inner end turns 502 and outer end turns 606 associated with only one of three phases for clarity. The positions of additional inner end turns 502 and outer end turns 606 that can 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.
• FIG. 12B thus illustrates how the windings for a single phase of a three phase stator can make their way through a stacked set of three subassemblies SI, S2, and S3, with each subassembly having four conductive layers.
• the subassemblies SI, 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.
• windings of the three subassemblies SI, S2, and S3 are connected in series so that the turn count for each phase of the entire assembly is three times greater than the turn count of any one of the individual subassemblies SI, S2, and S3.
• the current may then exit the windings of subassembly S2 via conductive traces 1212a and 1212b.
• Current from the conductive traces 1212a, 1212b may then flow through through-via 1206b to conductive traces 1214a and 1214b, where it may enter the windings of the subassembly S3.
• the current may then exit the windings of subassembly S3 and flow to a neutral conductor, along with currents from the other two phases (shown FIGS. 13A and 13B).
• FIGS. 13A-13B illustrate how the windings of the two remaining phases may work their way through the three subassemblies SI, S2, and S3 shown in FIG. 12 A, with the portions of the subassemblies corresponding to the other two phases removed for illustration purposes. Accordingly, FIG. 12B illustrates the positions of inner end turns 502b, 502e, 502i, and 5021 and outer end turns 606 for a first phase within the stack of three
• FIG. 13A illustrates the positions of inner end turns 502a, 502d, 502h, and 502k and outer end turns 606 for a second phase within the stack of three subassemblies SI, S2, and S3, and FIG. 13B illustrates the positions of inner end turns 502c, 502f, 502g, and 502i and outer end turns 606 for a third phase within the stack of three subassemblies SI, S2, and S3.
• Each subassembly SI, S2, and S3 comprises four conductive layers, like FIG. 10A, but the layer with outer end turns 606 of multiplicity two in each subassembly is different.
• the top subassembly SI has two parallel layers of outer end turns 606, but the other two subassemblies S2 and S3 do not;
• the bottom subassembly S3 has two parallel layers of outer end turns 606, but the other two subassemblies S2 and S3 do not; and for the phase illustrated in FIG.
• the middle subassembly S2 has two parallel layers of outer end turns 606, but the other two subassemblies SI and S3 do not. Accordingly, the stacked assembly shown by the combination of FIGS. 12A, 12B, 13A and 13B is arranged so that each of the three phases has the same number of parallel and series connected layers of outer turns 606, in addition to having the same number of parallel and series connected layers of inner end turns 502, thus making the overall assembly balanced.
• FIGS. 14, 15A, 15B, 15C, 16A, and 16B illustrate an example embodiment of a stator that employs serpentine windings like that shown in FIG. 9, and in which inner end turns 502 of the type shown in FIGS. 5A and B and outer end turns 706 of the type shown in FIGS. 7A and 7B are employed to establish all of the winding connections needed for three phases in an assembly that includes just two conductive layers.
• each of the radial connectors 404 on the upper conductive layer is connected to a corresponding (and parallel) radial connector 404 in the lower conductive layer using vias 1410, which are similar to the vias 310 shown in FIG. 3.
• FIG. 15A shows an expanded (in the z-axis) perspective view of only the portions of the assembly shown in FIG. 14 that correspond to a first phase of the stator.
• the first phase may employ inner end turns 502b, 502e, 502i, 5021 shown in FIGS. 5A and 5B, and outer end turns 706a, 706d, 706h, and 706k shown in FIGS. 7A and 7B.
• FIG. 15A thus illustrates how the windings for a single phase of a three phase stator can make their way through the assembly shown in FIG. 14.
• FIGS. 15B and 15C show, respectively, the portions of the upper and lower conductive layers shown in FIG. 15A that contribute to the windings for the first phase.
• FIGS. 16A and 16B illustrate how the windings of the two remaining phases can make their way through the assembly shown in FIG. 14, with the portions of the assembly corresponding to the other two phases removed for illustration purposes.
• a second phase may employ inner end turns 502a, 502d, 502h, 502k shown in FIGS. 5 A and 5B, and outer end turns 706c, 706f, 706g, and 706j shown in FIGS. 7 A and 7B.
• a third phase may employ inner end turns 502c, 502f, 502g, 502i shown in FIGS. 5 A and 5B, and outer end turns 706b, 706e, 706i, and 7061 shown in FIGS. 7 A and 7B.
• FIGS. 14, 15A, 15B, 16A, and 16B represents the practical limit of reducing the number of layers required for a complete three- phase stator. It should be appreciated, however, that for such a configuration some mechanism will be needed to establish an electrical connection from a driving circuit (not shown) to a location inside of the serpentine winding for each phase. For example, with reference to FIG. 15 A, an electrical connection will need to be made from such a driving circuit to the via 1410a (or another conductor), so as to allow the driving circuit to establish a complete circuit for the first phase. An electrical connection with the other end of the serpentine winding for the first phase can be established by way of through-via 1402b shown in FIG. 15 A.
• Such electrical connections may be established using any of several mechanisms, including through vias/solder pads/pressure contacts or pins to dedicated connection layers, connecting wires directly to the pads inside the outer end turns, or another similar technique.
• the maximum advantage of a two conductive layer approach like that illustrated in FIGS. 14, 15 A, 15B, 15C, 16A, and 16B— assuming that no additional layer is needed to effect an electrical connection— is that the number of turns per layer can be increased by a factor of three over a configuration like that described in '625 patent, or by a factor of two over the
• FIGS. 14, 15A, 15B, 15C, 16A, and 16B it should also be appreciated that it is also possible to stack two or more assemblies similar to that shown in FIGS. 14, 15A, 15B, 15C, 16A, and 16B, and connect the windings of those assemblies together, either in parallel or in series.
• the via 1410a shown in FIG. ISA could be connected to an "input" of serpentine winding of another, similar assembly having two conductive layers, e.g., using one of the connection techniques described in the preceding paragraph, thus establishing a series connection to additional turns for the first phase.
• such a serpentine winding in the second assembly may traverse a similar, e.g., counter-clockwise, serpentine path as the first assembly but may instead wind "out" toward an outermost outer end turn 706.
• An additional electrical connection could likewise be established from that outermost end turn of the second assembly to an input of yet another serpentine winding on yet another assembly having just two conductive layers, and that additional serpentine winding could, for example, traverse a similar, e.g., counter-clockwise, serpentine path as the second assembly but may again wind "in,” similar to the configuration of FIG. 15 A.
• Such a technique of winding "in” and then winding "out” on respective, series-connected layers could be repeated any number of times to continue to increase the turn count of the respective phases.
• two or more such respective assemblies may be laminated together to form a single planar composite structure (PCS).
• FIGS. 17A and 17B illustrate an example of a process for forming a multi-layer PCS assembly/subassembly 1700.
• the PCS assembly/subassembly 1700 includes four conductive layers CL1, CL2, CL3, and CL4, and three non-conductive dielectric layers DL1, DL2, and DL3. It should be appreciated, however, that the technique described may additionally or alternatively be used to form PCS subassemblies and/or subassemblies with different numbers of layers.
• two or more dielectric layers DL1, DL2, DL3 may be interleaved with multiple conductive layers CL1, CL2, CL3, CL4 and laminated together.
• the patterns 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 formed of an electrically conductive material, such as copper.
• Each conductive layer CL1, CL2, CL3, CL4 may be mechanically supported by at least one dielectric layer DL1, DL2, DL3.
• the dielectric layers may be formed of a non-conductive material, such as fiberglass.
• Each dielectric layer DL1, DL2, DL3 may thus electrically insulate a respective pair of the conductive layers CL1, CL2, CL3, CL4.
• each conductive layer CL1, CL2, CL3, CL4 may be produced by various methods including, but not limited to, etching, stamping, spraying, cutting, or machining.
• conductor patterns may be chemically etched into each side of a plurality of two-sided circuit boards, with each such circuit board including one sheet of fiberglass (e.g., dielectric layer DL1 or DL3 in FIG. 17A) sandwiched between two sheets of copper (e.g., CL1 and CL2 or CL3 and CL4 in FIG. 17A).
• a dielectric (e.g., fiberglass) sheet e.g., dielectric layer DL2 in FIG.
• the resulting PCS may, for example, be used as a stator for an axial flux motor or generator.
• a PCS of the type described above may employ copper sheets that are thicker than the copper sheets used in most commonly produced circuit boards.
• the copper sheets may have thicknesses ranging from 0.004 inches to 0.007 inches.
• Holes 1702 may be drilled in precise locations through one or more (or all) of the multiple circuit boards of a PCS 1700 and the inner walls of the holes may plated with a conductive material such as copper.
• the plated holes also known as vias (e.g., blind or buried vias 310 shown in FIG.
• the PCS 1700 may additionally include a center hole 1704 to accommodate a shaft of a rotor of an axial flux motor or generator, as described below.
• assemblies and/or subassemblies described herein can be employed in any known or future developed motor or generator, including the axial flux motors/generators described in the '625 patent, as well as the motors and generators described in U.S. Patent No. 9,673,688, U.S. Patent No. 9,673,684, and/or U.S. Patent No. 9,800,109, the entire contents of all of which are incorporated by reference above.
• FIG. 18A shows an example of a 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. 18B An expanded view showing these components and a means for their assembly is shown in FIG. 18B.
• the pattern of magnetic poles in the permanently magnetized portions 1806a, 1806b of the rotor assembly is also evident in the expanded view of FIG. 18B .
• FIG.18 A is an example of an embodiment where the electrical connections 1814 are taken at the outer radius of the PCS 1810, and the stator is mounted to a frame or case at the outer periphery.
• Another useful configuration involves mounting the stator at the inner radius, making electrical connections 1814 at the inner radius, and replacing the shaft 1808 with an annular ring separating the rotor halves. It is also possible to configure the system with just one magnet, either 1806a or 1806b, or to interpose 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. Not shown, but similar in purpose, an encoder attached to the shaft 1808 may provide position information to the controller 1812.
• the system 1800 in FIGS.18A and 18B can function either as a motor, or a generator, depending on the operation of the controller 1812 and components connected to the shaft 1808.
• the controller 1812 operates switches so that the currents in the stator 1810 create a torque about the shaft, due to the magnetic flux in the gap originating from the magnets 1804a, 1804b connected to the shaft 1808.
• the magnetic flux in the gap and/or the position of the rotor may be measured or estimated to operate the switches to achieve torque output at the shaft 1808.
• a source of mechanical rotational power connected to the shaft 1808 creates voltage waveforms at the terminals 1812 of the stator.
• These voltages can either be directly applied to a load, or they can be rectified with a three-phase (or poly phase) rectifier within the controller 1812.
• the rectifier implementation 1812 can be "self-commutated” using diodes in generator mode, or can be constructed using the controlled switches of the motor controller, but operated such that the shaft torque opposes the torque provided by the mechanical source, and mechanical energy is converted to electrical energy.
• an identical configuration in Figure 18A may function as both a generator and motor, depending on how the controller 1812 is operated.
• the controller 1812 may include filter components that mitigate switching effects, reduce EMI/RFI from the wires 1814, reduce losses, and provide additional flexibility in the power supplied to or delivered from the controller.
• the invention may be embodied as a method, of which an example has been provided.
• the acts performed as part of the method may be ordered in any suitable way.
• embodiments may be constructed in which acts are performed in an order different than illustrated, which may include performing some acts simultaneously, even though shown as sequential acts in illustrative embodiments.

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• Engineering & Computer Science (AREA)
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• Windings For Motors And Generators (AREA)
• Permanent Magnet Type Synchronous Machine (AREA)
• Superconductive Dynamoelectric Machines (AREA)
• Manufacture Of Alloys Or Alloy Compounds (AREA)

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