Magnetic material filled printed circuit boards and printed circuit board stators
AssigneeE-Circuit Motors, Inc.
InventorsGeorge Harder Milheim, Steven Robert Shaw, Ryan Terrence Duffy, Edward Charles Carignan
Life of this patent
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Abstract
A dielectric substrate may support conductive traces that form windings for a least one pole of a planar armature of an axial flux machine. At least a portion of the dielectric substrate, which is adapted to be positioned within an annular active area of the axial flux machine, may include a soft magnetic material. Such a planar armature may be produced, for example, by forming the conductive traces on the dielectric substrate, and filling interstitial gaps between the conductive traces with at least one epoxy material in which the soft magnetic material is embedded.
Claims14
A planar armature for an axial flux machine, the planar armature comprising:
- first and second conductive traces on a dielectric substrate, at least the first conductive traces forming windings for at least one pole of the planar armature, wherein:
- the first conductive traces are within an active area of the axial flux machine and first interstitial gaps between the first conductive traces are filled with a first non-conductive material in which a soft magnetic material is embedded, and
- the second conductive traces are outside of the active area and second interstitial gaps between the second conductive traces are filled with a second non-conductive material that is free of the soft magnetic material;
- and
- a dielectric layer disposed over the first and second conductive traces so that the first and second conductive traces are positioned between the dielectric substrate and the dielectric layer.
A method for forming a planar armature for an axial flux machine, the method comprising:
- forming first and second conductive traces on a dielectric substrate such that at least the first conductive traces form windings for at least one pole of the planar armature;
- filling first interstitial gaps located between the first conductive traces within an active area of the axial flux machine with a first non-conductive material in which a soft magnetic material is embedded;
- filling second interstitial gaps located between the second conductive traces outside the active area with a second non-conductive material that is free of the soft magnetic material;
- and
- disposing a dielectric layer over the first and second conductive traces so that the first and second conductive traces are positioned between the dielectric substrate and the dielectric layer.
Dependencies are inferred from the claim text.