3D-Printed Air Gap Winding Heads for Higher Power Density

The patent replaces conventional mechanical winding machines and forming processes with additive manufacturing technology. The air gap winding is produced directly through 3D printing of conductive materials, eliminating the need for complex mechanical winding operations and subsequent forming steps. This substitution of mechanical manufacturing with additive manufacturing directly resolves the contradiction by simplifying the overall manufacturing process while reducing device complexity.

The patent changes the fundamental manufacturing parameter from mechanical winding to additive deposition. By using conductive pastes or powders that can be directly printed in the desired geometry, the manufacturing approach transitions from subtractive/mechanical to additive, thereby simplifying the process and reducing the number of steps required while maintaining or improving winding quality.

The patent applies preliminary action by designing the winding head geometry directly in the additive manufacturing process. The radially protruding winding heads are created during the initial printing stage rather than through subsequent mechanical forming. This preliminary formation of the final geometry eliminates the need for damaging mechanical operations while preserving insulation integrity, thus resolving the contradiction between reliability and productivity.

The patent replaces mechanical forming operations with additive manufacturing to create the radially protruding winding heads. This substitution eliminates the mechanical contact that could damage insulation while achieving the desired geometry for improved active winding length to winding head ratio. The additive process directly forms the complex shapes without compromising conductor insulation, thereby maintaining reliability while enabling higher power density.

The patent replaces complex mechanical winding and forming operations with additive manufacturing to produce intricate winding head geometries. The 3D printing process can directly create complex radial and axial structures in a single operation, eliminating the need for multiple mechanical steps. This enables reduced winding head length for higher power density while managing manufacturing complexity through the capabilities of additive technology.

The patent utilizes the third dimension in additive manufacturing to create complex winding head geometries that would be difficult or impossible to achieve with conventional 2D winding machines. By printing in multiple layers and utilizing radial, axial, and circumferential directions, the process can produce optimized 3D winding head structures with reduced length while maintaining or improving performance, thereby resolving the contradiction between productivity and device complexity.

The patent replaces multiple sequential mechanical manufacturing steps with a single additive manufacturing process. The conductive materials are deposited layer by layer to form the complete winding structure in one integrated process, eliminating the need for separate winding, forming, and assembly operations. This substitution dramatically reduces the risk of insulation damage at each process interface while maintaining manufacturing feasibility, thus resolving the contradiction between reliability and ease of manufacture.

The patent merges multiple discrete manufacturing operations into a single additive manufacturing process. The winding body, winding heads, and internal structures are all created in one continuous printing operation rather than through separate steps. This consolidation eliminates the transitions between processes where insulation damage could occur, thereby improving operational safety while simplifying the overall manufacturing approach.