System and apparatus for axial field rotary energy device with alternative coil configuration

Abstract

An axial field rotary energy device can include a housing. A rotor can be mounted inside the housing. The rotor can include an axis of rotation and a magnet. A stator can be mounted inside the housing coaxial with the rotor. The stator can include a printed circuit board (PCB) having a PCB layer with a trace that is electrically conductive. The trace can include radial traces that extend in a radial direction relative to the axis and end turn traces that extend between the radial traces. The trace can include slits that extends through at least some portions of the trace.

We claim: 
     
         1 . An axial field rotary energy device, comprising:
 a housing;   a rotor mounted inside the housing, the rotor having an axis of rotation and a magnet;   a stator mounted inside the housing coaxial with the rotor, the stator comprising a printed circuit board (PCB) having a PCB layer with a trace that is electrically conductive, the trace comprises radial traces that extend in a radial direction relative to the axis and end turn traces that extend between the radial traces, and the trace comprises slits that extends through at least some portions of the trace.   
     
     
         2 . The axial field rotary energy device of  claim 1 , wherein the slits are in only the radial traces. 
     
     
         3 . The axial field rotary energy device of  claim 1 , wherein each of the slits is linear. 
     
     
         4 . The axial field rotary energy device of  claim 1 , wherein each of the slits is only linear, and the slits comprise no non-linear portions. 
     
     
         5 . The axial field rotary energy device of  claim 1 , wherein the trace is tapered in the radial direction relative to the axis. 
     
     
         6 . The axial field rotary energy device of  claim 5 , wherein the trace comprises an outer width that is adjacent an outer diameter of the PCB and in a plane that is perpendicular to the axis, the trace comprises an inner width that is adjacent an inner diameter of the PCB and in the plane, and the outer width is greater than the inner width. 
     
     
         7 . The axial field rotary energy device of  claim 5 , wherein the trace comprises inner and outer opposing edges, and entireties of the inner and outer opposing edges are not parallel to each other. 
     
     
         8 . The axial field rotary energy device of  claim 5 , wherein only the radial traces are tapered. 
     
     
         9 . The axial field rotary energy device of  claim 1 , wherein the trace comprises inner and outer opposing edges that are parallel to each outer. 
     
     
         10 . The axial field rotary energy device of  claim 1 , wherein the end turn traces are tapered. 
     
     
         11 . The axial field rotary energy device of  claim 1 , wherein the PCB layer comprises a PCB layer surface area, the trace on the PCB layer comprises a trace surface area that is in a range of at least about 75% to about 99% of the PCB layer surface area. 
     
     
         12 . An axial field rotary energy device, comprising:
 a housing;   a rotor mounted inside the housing, the rotor having an axis of rotation and a magnet; and   a stator mounted inside the housing coaxial with the rotor, the stator comprising a printed circuit board (PCB) having a PCB layer with coils, each coil comprises traces, at least some of the traces are tapered with inner and outer opposing edges that are not parallel to each other, and the traces comprise an outer width that is adjacent an outer diameter of the PCB and in a plane that is perpendicular to the axis, the traces comprise an inner width that is adjacent an inner diameter of the PCB and in the plane, and the outer width is greater than an inner width.   
     
     
         13 . The axial field rotary energy device of  claim 12 , the coils comprise slits that extend through at least some portions of the traces. 
     
     
         14 . The axial field rotary energy device of  claim 13 , the traces comprise radial traces that extend in a radial direction relative to the axis and end turn traces that extend between the radial traces. 
     
     
         15 . The axial field rotary energy device of  claim 14 , wherein only the radial traces are tapered. 
     
     
         16 . The axial field rotary energy device of  claim 15 , further comprising slits only in the radial traces. 
     
     
         17 . The axial field rotary energy device of  claim 16 , wherein each of the slits is only linear, and the slits comprise no non-linear portions. 
     
     
         18 . An axial field rotary energy device, comprising:
 a housing;   a rotor mounted inside the housing, the rotor having an axis of rotation and a magnet; and   a stator mounted inside the housing coaxial with the rotor, the stator comprising a printed circuit board (PCB) having a PCB layer with coils, each coil comprises traces, at least some of the traces are tapered, the traces comprise radial traces that extend in a radial direction relative to the axis and end turn traces that extend between the radial traces, and only the radial traces are tapered.   
     
     
         19 . The axial field rotary energy device of  claim 18 , further comprising linear slits only in the radial traces, the linear slits are only linear, and the linear slits comprise no non-linear portions. 
     
     
         20 . The axial field rotary energy device of  claim 19 , wherein at least some of the tapered radial traces comprise inner and outer opposing edges that are not parallel to each other, the traces comprise an outer width that is adjacent an outer diameter of the PCB and in a plane that is perpendicular to the axis, the traces comprise an inner width that is adjacent an inner diameter of the PCB and in the plane, and the outer width is greater than an inner width.