System and apparatus for modular axial field rotary energy device

Abstract

An axial field rotary energy device can include a housing having coupling structures configured to mechanically couple the housing to a second housing of a second module. In addition, the housing can include electrical elements configured to electrically couple the housing to the second housing. A rotor can be rotatably mounted to the housing. The rotor can include an axis and a magnet. A stator can be mounted to the housing coaxially with the rotor. The stator can include a printed circuit board (PCB) having a PCB layer comprising a coil.

1 . A module for an axial field rotary energy device, comprising:
 a housing having coupling structures configured to mechanically couple the housing to a second housing of a second module, and electrical elements configured to electrically couple the housing to the second housing;   a rotor rotatably mounted to the housing, and the rotor comprises an axis and a magnet; and   a stator mounted to the housing coaxially with the rotor, and the stator comprises a printed circuit board (PCB) having a PCB layer comprising a coil.   
     
     
         2 . The module of  claim 1 , wherein the rotor and the stator are located inside and surrounded by the housing. 
     
     
         3 . The module of  claim 1 , wherein the rotor comprises a plurality of rotors, the magnet comprises a plurality of magnets, and the stator comprises a plurality of stators, and each of the stators comprises a plurality of PCB layers, and each PCB layer comprises a plurality of coils. 
     
     
         4 . The module of  claim 1 , wherein the module is configured to be directly coupled to a frame, and the module is configured to he indirectly coupled to the second module. 
     
     
         5 . The module of  claim 1 , wherein the housing comprises a side wall that orients the stator at a desired angular orientation with respect to the axis. 
     
     
         6 . The module of  claim 5 , wherein the stator comprises a plurality of, stators, and the side wall comprises a plurality of side wall segments that angularly offset the plurality of stators at desired angular orientations with respect to the axis. 
     
     
         7 . The module of  claim 6 , wherein each side wall segment comprises a radial inner surface having a slot formed therein, the slot receives and maintains the desired angular orientation of the stator with respect to the axis, and the slots, collectively, hold outer edges of the stator at an air gap spacing between the stator and the rotor. 
     
     
         8 . The module of  claim 7 , wherein the stator is air cooled and is not liquid cooled. 
     
     
         9 . The module of  claim 8 , wherein the PCB layer comprises a plurality of PCB layers, each having a plurality of coils, each coil has only two terminals, each coil is continuous and uninterrupted between its only two terminals, and each coil is electrically coupled to another coil with a via. 
     
     
         10 . The module of  claim 9 , wherein two coils are coupled together to define a coil pair, and each coil pair is electrically coupled to another coil pair with another via. 
     
     
         11 . The module of  claim 10 , wherein the coils in each coil pair are located on different PCB layers. 
     
     
         12 . The module of  claim 10 , wherein each coil is coupled to another coil with only one via, and each coil pair is coupled to another coil pair with only one another via. 
     
     
         13 . The module of  claim 1 , wherein the stator comprises a plurality of stator segments, each of which comprises a PCB. 
     
     
         14 . The module of  claim 13 , wherein, the stator consists of only one electrical phase. 
     
     
         15 . The module of  claim 13 , wherein the stator comprises a plurality of electrical phases. 
     
     
         16 . A module for an axial field rotary energy device, comprising:
 a housing having coupling structures configured to mechanically couple the housing to a second housing of a second module, and electrical elements configured to electrically couple the housing to the second housing;   a plurality of rotors rotatably mounted to the housing, and the rotors comprise an axis and magnets; and   a plurality of stators mounted to the housing coaxially with the rotors, each stator comprises a printed circuit board (PCB) having a PCB layer comprising a coil, the stators are electrically coupled together inside the housing.   
     
     
         17 . A module for an axial field rotary energy device, comprising:
 a housing having coupling structures configured to mechanically couple the housing to a second housing of a second module, and electrical elements configured to electrically couple the housing to the second housing;   
       rotors rotatably mounted to the housing relative to an axis, and each the rotor comprises magnets; 
       stators mounted to the housing coaxially with the rotors, each of the stators comprises a printed circuit board (PCB) having PCB layers, and each PCB layer comprises coils; and 
       the housing comprises a plurality of side wall segments that orient the stators at desired angular orientations with respect to the axis, and angularly offset the stators at desired phase angles, wherein the side wall segments comprise radial inner surfaces having slots formed therein, the slots maintain the desired angular orientation and axial spacing of respective ones of the stators, and the slots, collectively, hold outer edges of the stators at desired air gap spacings between the stators and rotors. 
     
     
         18 . The module of  claim 17 , wherein the rotors and, stators are located inside and surrounded by the housing; and further comprising:
 a frame, the module is configured to be directly coupled to the frame, and the module is configured to be indirectly coupled to the second module.   
     
     
         19 . The module of  claim 17 , wherein each coil has only two terminals, each coil is continuous and uninterrupted between its only two terminals, and each coil is electrically coupled to another coil with a via. 
     
     
         20 . The module of  claim 17 , wherein each coil is coupled to another coil with only one via. 
     
     
         21 - 30 . (canceled)