A motor winding structure includes a base plate is disclosed. The base plate includes a board having a winding unit. The winding unit includes a plurality of coils formed on the surface of the board by electroforming or layout. Each coil has a center, and includes an inner end adjacent to the center and an outer end distant to the center. Two adjacent coils are connected to each other via the inner ends. The winding unit further includes an insulating layer and a conducting layer. The inner ends of the two coils are connected to an electrical connection pad. The insulating layer is arranged on the board. The two adjacent coils are covered by the insulating layer. The conducting layer extends through the insulating layer and is connected to the electrical connection pads of the two coils. The two coils are connected to each other via the inner ends.

Winding for an electrical machine having an inductor with pole pitch τ.sub.p, having a plurality of groups of turns intercepting a fraction of a magnetic field, each group comprising a first subgroup of turns and a second subgroup of turns of same phase at a distance equal to τ.sub.p, the turns of the first subgroup being connected in such a way that a current may flow in same direction in all turns of said subgroup, the turns of the second subgroup being connected in such a way that a current may flow in same direction in all turns of said subgroup, a turn of the first subgroup being connected to a turn of the second subgroup in such a way that the direction of said current in the first group is opposite to the direction of the current in the second subgroup.

Winding for an electrical machine having an inductor with pole pitch τ.sub.p, having a plurality of groups of turns intercepting a fraction of a magnetic field, each group comprising a first subgroup of turns and a second subgroup of turns of same phase at a distance equal to τ.sub.p, the turns of the first subgroup being connected in such a way that a current may flow in same direction in all turns of said subgroup, the turns of the second subgroup being connected in such a way that a current may flow in same direction in all turns of said subgroup, a turn of the first subgroup being connected to a turn of the second subgroup in such a way that the direction of said current in the first group is opposite to the direction of the current in the second subgroup.

An axial field rotary energy device has a PCB stator panel assembly between rotors with an axis of rotation. Each rotor has a magnet. The PCB stator panel assembly includes PCB panels. Each PCB panel can have layers, and each layer can have conductive coils. The PCB stator panel assembly can have a thermally conductive layer that extends from an inner diameter portion to an outer diameter portion thereof.

An axial field rotary energy device has a PCB stator panel assembly between rotors with an axis of rotation. Each rotor has a magnet. The PCB stator panel assembly includes PCB panels. Each PCB panel can have layers, and each layer can have conductive coils. The PCB stator panel assembly can have a thermally conductive layer that extends from an inner diameter portion to an outer diameter portion thereof.

The present invention discloses a winding structure and method having a high power density, and motor applying the above. The winding of the present invention has a multilayer 2D structure, has a distributed structure with an electrical angle of 180 degrees and is manufactured in the form of a PCB, wherein each layer arranged only one phase winding. Each phase windings contains 2 layers, or 4 layers, or other even layers, of windings. The number of coil cycles in every layer is the same as the motor poles, the winding layers of a same phase are connected via a through hole, the connecting hole is arranged at a corner of an upper portion of the winding loop inside.

The present invention discloses a winding structure and method having a high power density, and motor applying the above. The winding of the present invention has a multilayer 2D structure, has a distributed structure with an electrical angle of 180 degrees and is manufactured in the form of a PCB, wherein each layer arranged only one phase winding. Each phase windings contains 2 layers, or 4 layers, or other even layers, of windings. The number of coil cycles in every layer is the same as the motor poles, the winding layers of a same phase are connected via a through hole, the connecting hole is arranged at a corner of an upper portion of the winding loop inside.

The disclosure relates to printed circuit board motors and specifically to printed circuit boards used in motors and generators. Windings formed from copper on printed circuit boards have been used for purposes of forming antennas, inductors, transformers, and stators that can be incorporated in permanent magnet brushless DC (permanent magnet synchronous) machines. For energy conversion devices using modern permanent magnet materials and PCB stators, the magnetic field is not strongly confined by magnetically susceptible materials. Thus, the interaction between fields from adjacent turns in a winding, and/or windings on adjacent layers (for a multilayer configuration) may be significant. The structures disclosed hereinafter reduce the effective resistance in the windings, and therefore reduce the associated losses to achieve a reduced current density in portions of the rotating energy conversion devices. The effect of the disclosed structures is a measurable reduction in loss mechanisms as a function increasing frequency, compared to the currently available devices. These effects are significant in frequency ranges important to energy conversion processes as well as typical control strategies, for example, pulse-width modulation.

The disclosure relates to printed circuit board motors and specifically to printed circuit boards used in motors and generators. Windings formed from copper on printed circuit boards have been used for purposes of forming antennas, inductors, transformers, and stators that can be incorporated in permanent magnet brushless DC (permanent magnet synchronous) machines. For energy conversion devices using modern permanent magnet materials and PCB stators, the magnetic field is not strongly confined by magnetically susceptible materials. Thus, the interaction between fields from adjacent turns in a winding, and/or windings on adjacent layers (for a multilayer configuration) may be significant. The structures disclosed hereinafter reduce the effective resistance in the windings, and therefore reduce the associated losses to achieve a reduced current density in portions of the rotating energy conversion devices. The effect of the disclosed structures is a measurable reduction in loss mechanisms as a function increasing frequency, compared to the currently available devices. These effects are significant in frequency ranges important to energy conversion processes as well as typical control strategies, for example, pulse-width modulation.

The present document discloses motors and motor components that are constructed on a planar substrate. In some implementations, the planar substrate is made from rigid or semi-rigid sheet material, such as a printed circuit board (“PCB”). One or more coils are formed using spiral-shaped conductive traces that overlay the front and/or back surfaces of the substrate. In one implementation, a plurality of alternating right-hand and left-hand spiral-shaped conductive traces are separated by insulating layers, and connected with conductive vias to form inductive coils. Alternative coil-configurations include single-drive counter-wound coils and coils having a central ferrous or magnetic core.