Abstract: An axial field rotary energy device can include a rotor comprising an axis of rotation and a magnet. In addition, a stator can be coaxial with the rotor. The stator can include a plurality of stator segments that are coupled together about the axis. Each stator segment can include a printed circuit board (PCB) having a PCB layer comprising a coil. Each stator segment also can include only one electrical phase. The stator itself can include one or more electrical phases.

Abstract: A printed circuit board (PCB) has a tridimensional (3D) dielectric substrate having opposite sides and made of fiber-reinforced polymer. Each side comprises channels and pockets formed by molding or machining a dielectric laminate, and the channels and pockets define a layout for conductive traces and pads of the PCB. The channels and pockets in a same side of the 3D dielectric substrate have a uniform depth. Side walls of the channels and pockets have a draft angle in a range of at least about 5 degrees to at least about 15 degrees.

Abstract: An axial field rotary energy device can include a rotor having an axis of rotation and a printed circuit board (PCB) stator having PCB panels. Each PCB panel has conductive layers, each conductive layer has coils, and each coil has radial conductors and end turn conductors. The PCB stator also has conductive pads coupled to a temperature sensor. Each conductive pad is connected to a terminal through a respective conductive trace. The conductive pads are axially aligned or located directly adjacent to respective end turn conductors in a conductive layer that is separated from the end turn conductors by an insulation layer.

Abstract: An axial field rotary energy device can include a rotor comprising an axis of rotation and a magnet. In addition, a stator can be coaxial with the rotor. The stator can include a plurality of stator segments that are coupled together about the axis. Each stator segment can include a printed circuit board (PCB) having a PCB layer comprising a coil. Each stator segment also can include only one electrical phase. The stator itself can include one or more electrical phases.

Abstract: An axial field rotary energy device can include a housing and a rotor rotatably coupled to the housing. The rotor can have an axis of rotation and magnets. A stator assembly can be coupled to the housing coaxial with and adjacent to the rotor. The stator assembly can include a printed circuit board (PCB) having electrically conductive coils and an internal air duct for cooling the stator assembly.

Abstract: An axial field rotary energy device can include a rotor having an axis of rotation and a printed circuit board (PCB) stator having PCB panels. Each PCB panel has conductive layers, each conductive layer has coils, and each coil has conductive traces. A radial portion of the conductive traces are arranged to form spaces so vias coupled to one phase do not intersect coils from another phase. The PCB stator can have a contoured outer ring that is a uniform distance from an inner edge thereof to the outer edges of the coils.

Abstract: A method for making a printed circuit board (PCB) with a tridimensional (3D) dielectric substrate having opposite sides and made of fiber-reinforced polymer. Each side comprises channels and pockets formed by molding or machining a dielectric laminate, and the channels and pockets define a layout for conductive traces and pads of the PCB. The channels and pockets in a same side of the 3D dielectric substrate have a uniform depth. Side walls of the channels and pockets have a draft angle in a range of at least about 5 degrees to at least about 15 degrees.

Abstract: An axial field rotary energy device can include a rotor comprising an axis of rotation and a magnet. In addition, a stator can be coaxial with the rotor. The stator can include a plurality of stator segments that are coupled together about the axis. Each stator segment can include a printed circuit board (PCB) having a PCB layer comprising a coil. Each stator segment also can include only one electrical phase. The stator itself can include one or more electrical phases.

Abstract: An axial field rotary energy device or system includes an axis, a PCB stator and rotors having respective permanent magnets. The rotors rotate about the axis relative to the PCB stator. A variable frequency drive (VFD) having VFD components are coupled to the axial field rotary energy device. An enclosure contains the axial field rotary energy device and the VFD, such that the axial field rotary device and the VFD are integrated together within the enclosure. In addition, a cooling system is integrated with the enclosure to cool the axial field rotary energy device and the VFD.

Abstract: A system has an axial field rotary energy device with a housing, an axis and a rotor with a shaft, bearings, rotor disks and permanent magnets. A printed circuit board (PCB) stator is between the rotor disks to define an air gap on each side thereof. A variable frequency drive (VFD) assembly has a VFD housing and first pads coupled to inductors to facilitate heat removal from the inductors. A concave cradle is coupled to a ferromagnetic core and has a same contour as an outer surface of the ferromagnetic core. A second pad is coupled to a rectifier module. A third pad is coupled to switching devices and has pins to align the switching devices with the third pad. Standoffs are coupled to the VFD housing to support a first printed circuit board assembly (PCBA). A second PCBA is mounted to a shield plate above the first PCBA.

Abstract: A system can include an axial field rotary energy device with an axis of rotation and a rotor coaxial with the axis and having a shaft, bearings, rotor disks that are coaxial and permanent magnets on each rotor disk. A printed circuit board (PCB) stator is located between the rotor disks to define an air gap on each side of the PCB stator. An enclosure has two enclosure sections with an inspection port. Bearing caps and bearings are mounted to the rotor. A variable frequency drive (VFD) assembly is coupled to the axial field rotary energy device. The VFD has a flexible conduit that extends between the VFD housing and the axial field rotary energy device. The flexible conduit can adapt to different sizes of axial field rotary energy devices.

Abstract: A printed circuit board (PCB) has a dielectric substrate of fiber-reinforced polymer with opposite sides. Each side has channels formed by molding or machining the dielectric substrate. Conductive wires are inserted into the channels to define conductive traces.

Abstract: A device has a housing and rotors rotatably coupled to the housing. Each rotor has a magnet on at least one side of the rotor. Printed circuit board (PCB) stators are located axially between the rotors and coupled to the housing. The PCB stators have layers, and each layer has coils. The number of rotors disks is equal to the number of stators plus one. The stators are interleaved with the rotors. A shaft is coupled to the rotors and the housing. The shaft has a hollow section coupled to a source of a liquid coolant through a rotary connector and to radial channels in the shaft that dispense a liquid coolant between the rotors and PCB stators. The shaft has flanges with different diameters configured to receive the rotors disks with respective matching bore diameters. In addition, the housing has a sump to collect the liquid coolant.

Abstract: An axial field rotary energy device can include a rotor comprising an axis of rotation and a magnet. In addition, a stator can be coaxial with the rotor. The stator can include a plurality of stator segments that are coupled together about the axis. Each stator segment can include a printed circuit board (PCB) having a PCB layer comprising a coil. Each stator segment also can include only one electrical phase. The stator itself can include one or more electrical phases.

Abstract: A system has an axial field rotary energy device with a housing, an axis and a rotor with a shaft, bearings, rotor disks and permanent magnets. A printed circuit board (PCB) stator is between the rotor disks to define an air gap on each side thereof. A variable frequency drive (VFD) assembly has a VFD housing and first pads coupled to inductors to facilitate heat removal from the inductors. A concave cradle is coupled to a ferromagnetic core and has a same contour as an outer surface of the ferromagnetic core. A second pad is coupled to a rectifier module. A third pad is coupled to switching devices and has pins to align the switching devices with the third pad. Standoffs are coupled to the VFD housing to support a first printed circuit board assembly (PCBA). A second PCBA is mounted to a shield plate above the first PCBA.

Abstract: An axial field rotary energy device can include a housing and a rotor coupled to the housing. The rotor can include an axis of rotation and a rotor disk having a magnet. The device can include a stator that is coaxial with the rotor. The stator can include a printed circuit board having conductive layers laminated together with layers of an insulating material. Each conductive layer has coils that can carry electrical current when connected to an external voltage source. The stator is mechanically coupled to the housing, so the stator reacts to torque produced by the device. A ferromagnetic yoke is coaxial with the rotor and stator. The ferromagnetic yoke can be mechanically and thermally coupled to the stator and the housing to provide a path for magnetic flux produced by the magnet and a path to conduct heat generated by the stator from the stator to the housing.

Abstract: A device has a housing, stators and a rotor with an axis and rotor disks with magnets. Each stator has a printed circuit board with conductive layers laminated together with layers of an insulating material. Each conductive layer has coils that can carry electrical current when connected to an external voltage source. The stators are mechanically coupled to the housing, so the stators react to torque produced by the device. The housing has two end sections and mid-sections where the end sections are mechanically coupled a stator and a ferromagnetic yoke. The mid-sections are mechanically coupled to one or two stators and ferromagnetic yokes. The ferromagnetic yokes are coupled to the stators and to the housing to provide a path for magnetic flux produced by the magnets and a path to conduct heat generated by the stators from the stators to the housing.

Abstract: A printed circuit board (PCB) has a tridimensional (3D) dielectric substrate having opposite sides and made of fiber-reinforced polymer. Each side comprises channels and pockets formed by machining a dielectric laminate, and the channels and pockets define a layout for conductive traces and pads of the PCB. The channels and pockets in a same side of the 3D dielectric substrate have a uniform depth. Side walls of the channels and pockets have a draft angle in a range of greater than 0 degrees to about 5 degrees. The conductive traces and pads are formed into the channels and pockets by electrolytic metallization. In addition, the outer surface of conductive traces and pads are flush with the sides of the 3D dielectric substrate.

Abstract: A system can include an axial field rotary energy device with an axis of rotation and a rotor coaxial with the axis and having a shaft, bearings, rotor disks that are coaxial and permanent magnets on each rotor disk. A printed circuit board (PCB) stator is located between the rotor disks to define an air gap on each side of the PCB stator. An enclosure has two enclosure sections with an inspection port. Bearing caps and bearings are mounted to the rotor. A variable frequency drive (VFD) assembly is coupled to the axial field rotary energy device. The VFD has a flexible conduit that extends between the VFD housing and the axial field rotary energy device. The flexible conduit can adapt to different sizes of axial field rotary energy devices.

Abstract: An axial field rotary energy device can include a housing having an axis. A stator assembly is mounted to the housing and has stator panels that are axially-stacked and discrete panels from each other. Each stator panel includes a respective printed circuit board (PCB) having respective coils that are electrically conductive and interconnected within the respective PCB. In addition, a rotor assembly including rotors is rotatably mounted within the housing on opposite axial ends of the stator assembly. The rotors can be mechanically coupled together. Each rotor can include magnets having leading and trailing edges. The trailing edge of one magnet and the leading edge of an adjacent magnet can be parallel to each other to define a consistent circumferential spacing, relative to the axis, between adjacent ones of the magnets.