A coil system, including: pairs of planar coils vertically stacked in a vertical direction, each pair of planar coils including a first planar coil including a first outer turn and a second planar coil including a second outer turn overlapping the first outer turn and laterally offset from the first outer turn; and pairs of vertically stacked thermal conductor tracks, each pair of thermal conductor tracks including a first track and a second track overlapping the first track, laterally offset from the first track, and overlapping the first outer turns of the pairs of planar coils. The pairs of thermal conductor tracks are DC isolated from pairs of planar coils. The first outer turns and the second outer turns of the pairs of planar coils form a first comb-like structure. The plurality of pairs of thermal conductor tracks form a second comb-like structure engaged with the first comb-like structure.

A motor using a printed circuit board may include: a first base part forming a first circuit board on which a coil pattern is printed; a second base part forming a second circuit board on which the coil pattern is printed, the second base part spaced apart from the first base part; and a plurality of side parts forming side circuit boards on which the coil pattern is printed, the plurality of side parts connected to the first base part and the second base part, respectively, such that the coil pattern successively connects the first base part, the second base part, and the plurality of side parts.

Some embodiments include a camera voice coil motor (VCM) actuator that includes an additive coil structure for shifting a lens along one or multiple axes. The additive coil structure may include a base portion configured to couple with a lens carrier and at least partially surround a perimeter of the lens carrier. In various examples, the additive coil structure may include folded portions that individually include a respective coil that is located proximate a respective magnet. According to various embodiments, the additive coil structure may be formed using an additive process.

A printed coil assembly including a flexible dielectric material, a patterned top conductive layer formed on a top surface of the flexible dielectric material, and a patterned bottom conductive layer formed on a bottom surface of the flexible dielectric material. The patterned top conductive layer and the patterned bottom conductive layer form a plurality of printed coils arranged in a plurality of printed coil rollers concentrically arranged in a cylindrical shape. Each of the plurality of printed coils includes a top layer printed coil disposed within the patterned top conductive layer and a bottom layer printed coil disposed within the patterned bottom conductive layer. Coil pitches of the coils within each roller are chosen such that corresponding ones of the plurality of printed coils in adjacent rollers are axially aligned relative to a center of the cylindrical shape.

Methods of winding a serpentine pattern of a stator coil and structures made from the methods. In one embodiment, a method forms a serpentine winding from a bundle of wires with a first end and a second end, then joins a first group of in-hand conductors of the second end to a second group of in-hand conductors of the first end, the result of which electrically connects a first turn to a second turn. The successive turns of the coil are connected in the same manner. In one embodiment, a method forms a multiple phase serpentine winding, such as three-phases, with coplanar radial conductors. In one embodiment, a method includes a method of forming a serpentine winding on one or more layers of a printed circuit board (PCB). In one embodiment, a method uses plated slots adjacent one or more radial torque inducing conductors to electrically connect the radial conductors of one layer to one or more corresponding radially torque inducing conductor(s) on at least one other layer. In one embodiment, a method removes the electrically conductive material on at least one end of the plated slot in order to reduce looping electrical currents. In one embodiment, a method removes the electrically conductive material from each end of a plated slot so that a pair of radially torque inducing conductors are electrically connected in series.

An electric machine includes a plurality of permanent magnets and a plurality of conductors. The plurality of permanent magnets are arranged radially around a rotation axis of the electric machine and spaced apart from the rotation axis of the electric machine. At least one of the plurality of magnets has a shape in a plane of rotation intersected by the rotation axis. The plurality of conductors are arranged relative to the plurality of magnets and spaced apart from each other circumferentially around the rotation axis of the electric machine. At least one of the plurality of conductors includes a trace having a polygon shape different than the shape of the at least one of the plurality of magnets.

A method for producing an electrically conductive component having a cavity is described. An efficient production method for such a component, which allows a high variability of the wall thickness of the component, is implemented by applying a load-bearing layer consisting of an electrically conductive material to a soluble substrate and then dissolving and at least partially removing the substrate.

Methods of assembling motor windings comprising wrapping windings around a central longitudinal axis in a cylindrical shape having a plurality of annularly spaced positions such that the windings form n and/or u shapes around the positions. As the windings encircle the longitudinal axis, they are wrapped in an outward spiral or inward spiral such that each pass of the windings is stacked on a previous pass.

Electrical machines, components thereof, and methods for manufacturing the same are provided. In one aspect, methods for additively manufacturing a rotor assembly for an electrical machine is provided. The method includes additively printing the rotor core and shaft of the same material composition. In another aspect, an electrical machine is provided. The electrical machine includes a stator assembly that includes a stator core having a plurality of poles with magnetic slot wedges positioned between adjacent poles to reduce tooth harmonics. The electrical machine also includes a rotor assembly having a rotor core that is formed as a solid core. In yet another aspect, a rotor assembly for an electrical machine is provided that includes slots that reduce eddy current losses in the rotor core during operation of the electrical machine.

A method for fabricating a composite lens holder with low-mass conductive metal and high-precision placement thereof to enable smaller-scale fabrication includes the steps of forming a plastic lens holder as a matrix, laser etching an outer surface of the plastic lens holder to form surface patterns, and electroless plating of metal on the surface patterns to form an effective coil, thereby producing the composite lens holder. A voice coil motor and an electronic device which use such a composite lens holder are also disclosed.