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

Abstract

An axial field rotary energy device can include a rotor having an axis of rotation and magnets. Each magnet can extend in a radial direction relative to the axis. Each magnet can include a magnet radial edge. The device also includes a stator that is coaxial with the rotor. The stator has printed circuit board (PCB) layers each having coils. Each coil has a coil radial edge. When the radial edge portions of the magnets and the coils rotationally align relative to the axis, the magnet radial edges and the coil radial edges are not parallel and are angularly skewed relative to each other.

We claim: 
     
         1 . An axial field rotary energy device, comprising:
 a rotor comprising an axis of rotation and a plurality of magnets, each magnet extends in a radial direction relative to the axis, and each magnet comprises a magnet radial edge;   a stator coaxial with the rotor, the stator comprises a plurality of printed circuit board (PCB) layers each having a plurality of coils, and each coil comprises a coil radial edge; and   when radial edge portions of the magnets and coils rotationally align relative to the axis, the magnet radial edges and coil radial edges are not parallel and are angularly skewed relative to each other.   
     
     
         2 . The axial field rotary energy device of  claim 1 , wherein the angular skew is at least about 0.1 degrees. 
     
     
         3 . The axial field rotary energy device of  claim 1 , wherein the angular skew is at least about 1 degree. 
     
     
         4 . The axial field rotary energy device of  claim 1 , wherein the angular skew is not greater than about 25 degrees. 
     
     
         5 . The axial field rotary energy device of  claim 4 , wherein the magnet radial edges and coil radial edges are leading radial edges or trailing radial edges of the magnets and coils, respectively. 
     
     
         6 . The axial field rotary energy device of  claim 5 , wherein each of the magnet radial edges and coil radial edges are linear, and no portions of the magnet radial edges and coil radial edges are parallel when the radial edge portions of the magnets and coils rotationally align with respect to the axis. 
     
     
         7 . The axial field rotary energy device of  claim 1 , wherein when the radial edge portions of the magnets and coils rotationally align, at least some portions of the magnet radial edges and coil radial edges are parallel to each other. 
     
     
         8 . The axial field rotary energy device of  claim 1 , wherein the magnet radial edges and coil radial edges are not entirely linear. 
     
     
         9 . An axial field rotary energy device, comprising:
 a rotor comprising an axis of rotation and magnets, and each magnet has a magnet radial edge;   a stator coaxial with the rotor, the stator comprises a plurality of stator segments coupled together about the axis, each stator segment comprises a printed circuit board (PCB) having a PCB layer comprising a coil, and each coil has a coil radial edge; and   when radial edge portions of the magnets and coils rotationally align relative to the axis, the magnet radial edges and coil radial edges are not parallel and are angularly skewed relative to each other.   
     
     
         10 . The axial field rotary energy device of  claim 9 , wherein the angular skew is at least about 0.1 degrees. 
     
     
         11 . The axial field rotary energy device of  claim 9 , wherein the angular skew is at least about 1 degree. 
     
     
         12 . The axial field rotary energy device of  claim 9 , wherein the angular skew is not greater than about 25 degrees. 
     
     
         13 . The axial field rotary energy device of  claim 9 , wherein said at least portions of the magnet radial edges and coil radial edges are leading radial edges or trailing radial edges of the magnets and coils, respectively. 
     
     
         14 . The axial field rotary energy device of  claim 9 , wherein each of the magnet radial edges and coil radial edges are linear, and no portions of the magnet radial edges and coil radial edges are parallel when said at least portions of the magnets and coils rotationally align. 
     
     
         15 . The axial field rotary energy device of  claim 9 , wherein when said at least portions of the magnets and coils rotationally align, at least portions of the magnet radial edges and coil radial edges are parallel to each other. 
     
     
         16 . The axial field rotary energy device of  claim 9 , wherein the magnet radial edges and coil radial edges are not entirely linear. 
     
     
         17 . A module for an axial field rotary energy device, comprising:
 a housing configured to mechanically couple the housing to a second housing of a second module, and electrically couple the housing to the second housing;   a rotor rotatably mounted to the housing, the rotor comprises an axis and a magnet, and the magnet has a magnet radial edge;   a stator mounted to the housing coaxially with the rotor, the stator comprises a printed circuit board (PCB) having a PCB layer with a coil, and the coil has a coil radial edge; and   when radial edge portions of the magnet and coil rotationally align relative to the axis, at least radial edge portions of the magnet radial edge and coil radial edge are not parallel and are angularly skewed relative to each other.   
     
     
         18 . The axial field rotary energy device of  claim 17 , wherein the angular skew is at least about 0.1 degrees, and the angular skew is not greater than about 25 degrees. 
     
     
         19 . The axial field rotary energy device of  claim 18 , wherein the magnet radial edge and coil radial edge are a leading radial edge or trailing radial edge of the magnet and coil, respectively. 
     
     
         20 . The axial field rotary energy device of  claim 19 , wherein the magnet radial edge and coil radial edge are linear, and no portions of the magnet radial edge and coil radial edge are parallel when the radial edge portions of the magnet and coil rotationally align.