An assembly and method of manufacturing the coil assembly is provided. The method includes acquiring a sheet of a conductive metal and producing a plurality of coils from the sheet of conductive metal. Further, the method includes layering at least two of the plurality of coils with an insulation layer there between to construct the coil assembly and electrically coupling the at least two of the plurality of coils within the coil assembly.

A coil substrate includes a flexible substrate having a first end and a second end on the opposite side with respect to the first end, and coils formed on the flexible substrate such that the coils are positioned substantially in a row between the first end and second end of the flexible substrate. The coils are formed such that the number of coils is K and that the coils include the first coil positioned close to the first end and the K-th coil positioned to form a predetermined distance between the K-th coil and the second end, where K is an integer equal to or greater than 2.

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 method of making a component of an electrical machine is provided. An additive manufacturing process is used to manufacture a part, including applying beams of energy to a successive plurality of ferromagnetic material particles and fusing them together to form a ring or segment of a ring with an axis, a solid portion, and laminas that extend from the solid portion in a radial or axial direction.

A motor includes a stator and a rotor having an axis of rotation and a magnet. The stator includes a PCB having PCB panels. Each PCB panel is assigned to one electrical phase. Each PCB panel has a pair of PCB layers. Each PCB layer includes coils, and each coil in each PCB layer of a PCB panel is circumferentially aligned with a corresponding coil in another PCB layer. One coil in one PCB layer is coupled to a corresponding coil in another PCB layer with a via. A number of turns in each coil is a multiple of a number of electrical phases configured for the PCB stator. In addition, the vias that connect two coils in a pair of PCB layers that belong to a same electrical phase do not intersect coils in PCB layers that belong to other electrical phases of the PCB stator.

A motor includes a stator and a rotor having an axis of rotation and a magnet. The stator includes a PCB having PCB panels. Each PCB panel is assigned to one electrical phase. Each PCB panel has a pair of PCB layers. Each PCB layer includes coils, and each coil in each PCB layer of a PCB panel is circumferentially aligned with a corresponding coil in another PCB layer. One coil in one PCB layer is coupled to a corresponding coil in another PCB layer with a via. A number of turns in each coil is a multiple of a number of electrical phases configured for the PCB stator. In addition, the vias that connect two coils in a pair of PCB layers that belong to a same electrical phase do not intersect coils in PCB layers that belong to other electrical phases of the PCB stator.

A coil structure for an electromagnetic device comprising a conductor configured to provide a coil comprising one or more coil turns around a magnetic core to induce a magnetic flux in the magnetic core when in use. The conductor comprises one or more a first parts comprising a plurality of sub-conductors in parallel, and one or more second parts coupled in series with the first part(s), wherein the or each second part comprises a single sub-conductor or a lesser number of sub-conductors in parallel.

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 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.

A method of producing an electromagnetic mat for forming a stator or rotor component of an electric machine. The electromagnetic mat has structural fibre lengths and a plurality of winding fibre lengths for forming a winding fibre that is in a winding pattern for forming one or more windings of the electric machine. The electromagnetic mat is formed by forming a support structure with the structural fibre lengths and inserting the winding fibre lengths into the support structure so that the winding fibre lengths extend across the structural fibre lengths and the structural fibre lengths lock the winding fibre lengths in position.