The invention relates to a method for producing a wave winding for forming a coil winding (30) with at least one wave winding layer (33a, b) in a stator or rotor element (100), wherein a winding former (10) is provided with at least two winding sections (13a, b, c) and such that it can be rotated about a longitudinal axis (11), comprising the following method steps: Applying parallel coil wires to a first side (15) of the winding former (10) in a winding section (13) of the winding former (10); forming winding heads (31a, b) by alternately axially shifting the parallel coil wires on the winding former (10) and winding same about the rotated winding former (10); repeating steps a and b until the wave winding has reached a length of a first wave winding layer (33a) of the coil winding (30), wherein, according to the invention, the steps a to c are repeated in another winding section (13b) with a different winding width (12b). The invention also relates to a winding former (10) for producing a wave winding of this type which is suitable for introduction into grooves of a stator or rotor element (100).

As wire is wound around and onto the surface of a former to form a coil, perturbations such as waves are introduced into turns of the coil, each perturbation being formed in a length of the wire less than the full length of a respective turn and projecting along the former surface, the perturbation having an initial shape and size. The coil is taken from the former and fixed in form. A surrounding jacket is radially collapsed onto the wire coil to uniformly press the coil against an internal compressible body in the course of which the overall diameter of the coil is reduced. Resulting stresses in the wire generated during the collapse are relieved by alteration of the perturbations from their initial shape and size to a subsequent shape and size.

As wire is wound around and onto the surface of a former to form a coil, perturbations such as waves are introduced into turns of the coil, each perturbation being formed in a length of the wire less than the full length of a respective turn and projecting along the former surface, the perturbation having an initial shape and size. The coil is taken from the former and fixed in form. A surrounding jacket is radially collapsed onto the wire coil to uniformly press the coil against an internal compressible body in the course of which the overall diameter of the coil is reduced. Resulting stresses in the wire generated during the collapse are relieved by alteration of the perturbations from their initial shape and size to a subsequent shape and size.

A method for producing a spiral-shaped body, in particular an electric coil, made of an electrically conductive material. First, the material is wound about a mandrel in a casting mold in order to form a coil with a plurality of windings, and pressure is then exerted onto the coil in the axial direction of the coil. The pressure leads to a deformation and compression of the cross-section of the individual windings in the axial direction of the coil. By compressing the coil, an optimal use of space is achieved with an electric coil, for example for an electric machine.

A method for producing a spiral-shaped body, in particular an electric coil, made of an electrically conductive material. First, the material is wound about a mandrel in a casting mold in order to form a coil with a plurality of windings, and pressure is then exerted onto the coil in the axial direction of the coil. The pressure leads to a deformation and compression of the cross-section of the individual windings in the axial direction of the coil. By compressing the coil, an optimal use of space is achieved with an electric coil, for example for an electric machine.

This invention entails the use of fractal shapes as cores for electromagnets, and a concurrent shape of a fractal for the windings which surround it. The novelty of this invention lies not only with the shaping, but the advantage of such shaping, which includes producing a smaller form factor electromagnet for the same desired magnetic field strength, when compared to a conventional electromagnet. It will be appreciated that a range of devices including electromagnets, based on such fractal shaping, are additionally novel and include but are not limited to solenoid switches, relays, and other devices in which the fractal electromagnets are used to make a change in state of some device.

This invention entails the use of fractal shapes as cores for electromagnets, and a concurrent shape of a fractal for the windings which surround it. The novelty of this invention lies not only with the shaping, but the advantage of such shaping, which includes producing a smaller form factor electromagnet for the same desired magnetic field strength, when compared to a conventional electromagnet. It will be appreciated that a range of devices including electromagnets, based on such fractal shaping, are additionally novel and include but are not limited to solenoid switches, relays, and other devices in which the fractal electromagnets are used to make a change in state of some device.

The present invention relates high power AC steering flux cancelling inductors and processes of making and using same. When properly configured and wired such inductors, separate the AC component and DC component of a high power current thus allowing the smaller AC fraction of the overall current to be carried by much smaller cross-sectional litz wires. Such high power AC steering flux cancelling inductors are more efficient at avoiding core saturation compared to standard inductors, yet they are less expensive without the need for large cross-sectional litz AC carrying wires. In addition to the aforementioned benefits, such high power AC steering flux cancelling inductor permits the levels of AC and DC current to be efficiently monitored as such currents are separated.

The present invention relates high power stacked flux cancelling inductors and processes of making and using same. When properly configured and wired, such inductors separate the AC component and DC component of a high power current thus allowing the smaller AC fraction of the overall current to be carried by much smaller cross-sectional litz wires. Such high power stacked flux cancelling inductors are more efficient at avoiding core saturation compared to standard inductors, yet they are less expensive without the need for large cross-sectional litz AC carrying wires. In addition to the aforementioned benefits, such high power stacked flux cancelling inductor permits the levels of AC and DC current to be efficiently monitored as such currents are separated.

This invention entails the use of fractal shapes as cores for electromagnets, and a concurrent shape of a fractal for the windings which surround it. The novelty of this invention lies not only with the shaping, but the advantage of such shaping, which includes producing a smaller form factor electromagnet for the same desired magnetic field strength, when compared to a conventional electromagnet. It will be appreciated that a range of devices including electromagnets, based on such fractal shaping, are additionally novel and include but are not limited to solenoid switches, relays, and other devices in which the fractal electromagnets are used to make a change in state of some device.