INFINITUM ELECTRIC, INC.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.