System and apparatus for modular axial field rotary energy device

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;
• a plurality of stators mounted to the housing coaxially with the rotors, each stator comprises a printed circuit board (PCB) having a plurality of PCB layers, each PCB layer comprising a respective plurality of coils that are co-planar and angularly and symmetrically spaced apart from each other relative to the axis, each coil on a given PCB layer is entirely non-overlapping with other coils on the given PCB layer, each coil is continuous and concentric in a single plane from an outermost coil portion to a concentric innermost coil portion, the coils in adjacent PCB layers are circumferentially aligned with each other relative to the axis to define symmetric stacks of coils in an axial direction, the stators are electrically coupled together inside the housing;
• each coil has only two terminals for electrical connections, each coil on a given PCB layer is continuous and uninterrupted between its only two terminals, wherein no two adjacent coils on a given PCB layer are directly connected, but rather the adjacent coils of every pair of adjacent coils on the given PCB layer are coupled together through one or more coils on one or more other PCB layers, so that a current flowing through a given coil on a given PCB layer flows through at least one coil on another PCB layer before flowing through an adjacent coil on the given PCB layer;
• wherein
• the coils are series-connected within each layer pair, with no coil pair having both coils on the same PCB layer;
• and
• the layer pairs are series-connected.

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 relative to an axis, and each the rotor comprises magnets;
• a plurality of stators mounted to the housing coaxially with the rotors, each of the stators comprises a printed circuit board (PCB) having a plurality of PCB layers, each PCB layer comprises a respective plurality of coils that are co-planar and angularly and symmetrically spaced apart from each other relative to the axis, each coil on a given PCB layer is entirely non-overlapping with other coils on the given PCB layer, each coil is continuous and concentric in a single plane from an outermost coil portion to a concentric innermost coil portion, the coils in adjacent PCB layers are circumferentially aligned with each other relative to the axis to define symmetric stacks of coils in an axial direction;
• and
• a current flowing in a given rotational direction around a first coil on a given PCB layer likewise flows in the given rotational direction around a second coil adjacent to the first coil and disposed on the given PCB layer, so that the direction of current flow in an outermost radial trace of the first coil is opposite the direction of current flow in an adjacent outermost radial trace of the adjacent second coil.