Motor, flat-wire motor winding, coil winding assembly, and winding method

Patent metadata

Field	Value
Publication number	US-12184140-B2
Application number	US-202218086547-A
Country	US
Kind code	B2
Filing date	Dec 21, 2022
Priority date	Dec 7, 2020
Publication date	Dec 31, 2024
Grant date	Dec 31, 2024

Abstract

A motor winding includes a wire defining a rectangular cross-section and wound in a continuous direction about a coil axis to form a continuous coil including: a first coil segment spiraling in a first plane, defining a first external terminal, and defining a first interior end inset from the first external terminal and arranged on a first side of a coil axis; a second coil segment spiraling in a second plane parallel and offset from the first plane, defining a second exterior terminal parallel to the first external terminal, and defining a second interior end inset from the second exterior coil end and arranged on a second side of the coil axis opposite the first interior end; and a junction extending between the first plane and the second plane to couple the first interior end of the first coil segment to the second interior end of the second coil segment.

First claim

We claim:

1. A motor winding comprising:
a wire:
defining a wire width along a primary wire axis;
defining a wire thickness along a secondary wire axis, the wire thickness less than the wire width; and
wound in a continuous angular direction about a coil axis to form a continuous coil comprising:
a first terminal;
a second terminal adjacent the first terminal;
a first coil segment:
comprising a first length of the wire spiraling in a first plane parallel to the secondary wire axis and perpendicular to the primary wire axis of the first length of the wire;
defining a first exterior coil end coupled to the first terminal; and
defining a first interior coil end inset from the first exterior coil end and arranged on a first side of the coil axis;

a second coil segment:
comprising a second length of the wire spiraling in a second plane parallel to the secondary wire axis and perpendicular to the primary wire axis of the second length of the wire, the second plane parallel and offset from the first plane;
defining a second exterior coil end coupled to the second terminal; and
defining a second interior coil end:
 inset from the second exterior coil end; and
 arranged on a second side of the coil axis opposite the first interior coil end; and

a junction segment:
comprising a third length of the wire extending between the first plane and the second plane to couple the first interior coil end of the first coil segment to the second interior coil end of the second coil segment.

2. The motor winding of claim 1 :
wherein the wire comprises a solid unitary conductive structure;
wherein the second length of the wire is contiguous with the first length of the wire; and
further comprising a non-conductive coating encasing the wire.

3. The motor winding of claim 1 , wherein the continuous coil:
defines a rectangular orifice:
coaxial with the coil axis; and
configured to receive an annular core defining a rectangular core cross-section;

is configured to install over the annular core between:
a pair of stator poles; and
a second continuous coil and a third continuous coil geometrically analogous to the continuous coil; and

cooperates with the pair of stator poles, the second continuous coil, the third continuous coil, and the annular core to define a coil winding assembly within an electric motor.

4. The motor winding of claim 3 , wherein the first terminal and the second terminal are configured to couple directly to interconnects on a motor control board:
to retain the continuous coil in a longitudinal and radial position relative to a motor rotor; and
to source electrical current to the first continuous coil.

5. The motor winding of claim 1 :
wherein the first coil segment comprises:
a set of vertical linear sections, each vertical linear section in the set of vertical linear sections defining a common section height;
a set of horizontal linear sections, each horizontal linear section in the set of horizontal linear sections defining a common section length less than the common section height; and
a set of arcuate sections connecting the set of vertical linear sections and the set of horizontal linear sections, each arcuate section in the set of arcuate sections defining a common radial angle of 90°;

wherein an innermost arcuate section, in the set of arcuate sections, is connected to the junction segment and defines a last bend radius approximating a minimum bend radius of the wire; and
wherein an outermost arcuate section, in the set of arcuate sections and connected to the first terminal, defines a first bend radius greater than the last bend radius.

6. The motor winding of claim 1 :
wherein the first coil segment defines a rectangular coil cross-section in the first plane, the rectangular coil cross-section defining:
a vertical coil axis; and
a horizontal coil axis;

wherein the first coil segment comprises:
a set of vertical linear sections extending parallel to the vertical coil axis, each vertical linear section in the set of vertical linear sections defining a common section height; and
a set of horizontal linear sections extending parallel to the horizontal coil axis, each horizontal linear section in the set of horizontal linear sections defining a common section length less than the common section height; and

wherein the junction segment defines the third length greater than the common section height and less than a sum of the common section height and the wire thickness.

7. The motor winding of claim 6 , wherein the first coil segment further comprises:
a set of arcuate sections connecting the set of vertical linear sections and the set of horizontal linear sections, each arcuate section in the set of arcuate sections:
defining a common radial angle of 90°; and
characterized by a bend radius:
narrower than a preceding bend radius of a preceding arcuate section, in the set of arcuate sections along the first length of the wire, by one-fourth of the wire thickness; and
wider than a succeeding bend radius of a succeeding arcuate section, in the set of arcuate sections along the first length of the wire, by one-fourth of the wire thickness.

8. The motor winding of claim 1 :
wherein the first coil segment comprises:
a set of vertical linear sections; and
a set of horizontal linear sections;

wherein, in a relaxed configuration following removal of the wire from a mandrel:
the wire defines a segmented helical path about the coil axis;
the second terminal is nonparallel to the first terminal; and
the set of linear vertical sections are nonparallel; and

wherein, in a tensioned configuration of the wire:
the wire is tensioned about the coil axis:
to locate the second terminal adjacent and parallel to the first terminal; and
to locate the set of vertical linear sections perpendicular to the set of horizontal linear sections; and

the first coil segment is compressed against the second coil segment parallel to the coil axis to:
center the set of vertical linear sections and the set of horizontal linear sections of the first coil segment within the first plane; and
center the second coil segment within the second plane.

9. The motor winding of claim 8 , wherein the wire:
is wound about the mandrel comprising:
a first rectangular helical ramp section defining a pitch approximating the width of the wire and spiraling inwardly to form the first coil segment; and
a second rectangular helical ramp section spiraling outwardly to form the second coil segment; and

enters the relaxed configuration when removed from the mandrel.

10. The motor winding of claim 8 , further comprising a potting material encasing the wire and retaining the wire in the tensioned configuration.

11. The motor winding of claim 1 , wherein the first coil segment comprises the first length of the wire spiraling in the first plane offset from the second plane by the wire width.

12. The motor winding of claim 1 , wherein the wire:
comprises a solid unitary conductive structure; and
defines a rectangular wire cross-section.

13. The motor winding of claim 1 , wherein the wire:
is arranged adjacent and radially offset from a second motor winding 501 in a motor coil assembly, the second motor winding 501 comprising a second wire:
wound in the continuous angular direction about a second coil axis to form a second coil section comprising:
a third terminal;
a fourth terminal adjacent the third terminal;
a third coil segment;
comprising a fourth length of the second wire;
defining a third exterior coil end coupled to the third terminal; and
defining a third interior coil end i

Assignees

• Linear Labs Llc
• Linear Labs Inc

Inventors

• Hatch Erik
• Langsdorf John
• Barbu Cosmin Gheorghe

Classifications

• H02K15/08

  Forming windings by laying conductors into or around core parts · CPC title

• H02K1/16

  Stator cores with slots for windings · CPC title

• H02K1/145

  having an annular coil, e.g. of the claw-pole type · CPC title

• H02K21/125

  having an annular armature coil (H02K21/14 - H02K21/24 take precedence) · CPC title

• H02K2201/12

  Transversal flux machines · CPC title