A solid motor coil with conductive pathways as part of a unitary construction. The conductive pathways are separated by resistive insulating layers. The conductive pathways may vary in their location within the cross-section of the motor coil, which may significantly reduce eddy current losses. The solid motor coil may result in a higher packing factor than previous designs. The solid motor coil may reduce the eddy current loss per conductor, with commensurate reduction in peak temperature rise. An electric motor with solid motor coils provides improved heat conduction and improved efficiency, allowing for a smaller motor package at higher power levels.

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.

In an armature coil according to the present invention and, more particularly, in an armature coil including a plurality of coil conductors wound around a plurality of slots which are formed in a stator core and opened on the radially inner side, the circumferential width of the plurality of the coil conductors is formed in a substantially trapezoidal shape which gets narrower toward the radially inner side and the cross-sectional areas of the plurality of the coil conductors in the slot are each substantially the same and the circumferential width thereof is formed narrower as the coil conductor is arranged toward the radially inner side; and one coil conductor is formed in a convex shape and another coil conductor is formed in a concave shape along the convex shape.

A method and arrangement is disclosed herein for making a stator with 3D printed end turns. The stator includes a stator lamination stack with semi-closed slots. Straight I-pin wire segments are housed in the slots of the stator lam stack and form the in-slot segments of a stator winding arrangement. The end turns of the winding arrangement are provided by a conductive material that is 3D printed material at both axial ends of the straight I-pins. The end turns result in a winding arrangement with diamond coils that are inter-locked. The 3D printing of the end turns makes the winding arrangement possible, as the winding arrangement is configured such that it cannot be inserted into the lamination stack in a radial direction (i.e., via any slot openings at the inner diameter or outer diameter).

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.

A stator constructed for an electrical machine and operable at an electrical power of at least 1 MW includes a hollow-cylinder-shaped stator yoke defining an axis and having a radially inner side formed with an open groove which extends in an axial direction. Disposed in surrounding relation to the stator yoke is a toroidal coil which includes a groove segment arranged in the open groove, a back segment arranged on a radially outer face of the stator yoke, and axial end faces, with each axial end face having a radial segment to connect the groove segment to the back segment.

A method for manufacturing a stator for a rotary electric machine, capable of reducing a space on an end surface of a stator core on an inner diameter side to reduce a size in an axial direction to realize a compact size by maintaining an insulating distance corresponding to a potential difference. In the stator for the rotary electric machine a coil portion includes a coil main-body portion (21) and a second connecting wire (23). The second connecting wire (23) includes a first bent portion (24) and a second connecting-wire end portion (23A). The second connecting wire (23) is configured so that a differential value of a length z in the axial direction of the stator to a length r in the radial direction of the stator is z/r>0.

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.

The present invention provides a stator of a disc-type motor and a winding method thereof. A circle of coil units (20) filled into coil slots (1) are arranged on a disc-shaped stator disc (12); jumper wire slots (10), fly wire slots (3) and jumper wire joint holes (7) are formed in the radial outer sides of the coil slots (1); and the coils are wound, overlapped and filled into the coil slots in a disc shape and are connected with one another in series by connecting wires embedded into the stator disc (12) in the same current direction.

A stator winding includes a plurality of conductors including ducts. The ducts can be connected to a heat pipe or a conduit providing a coolant flow to directly cool the winding. The heat pipe can be connected to a heat exchanger that includes a coolant flow. The stator winding can be produced using additive manufacturing, with hollow ducts extending through leg sections and solid end sections. The heat exchanger can also be additively manufactured. A circuit for driving an electrical machine can be in thermal communication with the heat exchanger, such that the thermal system manages both the stators and the drive circuit.