Helical Stator Windings for Electric Aircraft Motor Thermal Management

The mandrel structure integrates multiple functions into a single component: it provides the structural framework for winding placement, incorporates electrically insulating guide walls directly into its surface, and serves as the core around which copper windings are wound. This merging of functions reduces the number of separate components needed, thereby improving volumetric efficiency while maintaining structural complexity at an acceptable level.

The guide walls extend in the axial dimension of the mandrel, creating three-dimensional channels that allow copper windings to be positioned in multiple spatial layers. This dimensional approach enables more copper windings to be packed into the available volume without simply increasing the radial or circumferential dimensions, thereby increasing power output while controlling weight growth.

The guide walls create localized channels with specific geometric properties that differ from the surrounding winding areas. These channels provide dedicated thermal pathways with different thermal conductivity characteristics, allowing heat to be managed locally in high-density winding regions while maintaining overall power density. The local structural variation enables targeted thermal management without compromising power density.

The mandrel is designed as a multi-functional component that simultaneously provides structural support, winding guidance, and electrical insulation through its integrated guide walls. By making the mandrel itself electrically insulating and multi-functional, the design eliminates the need for separate insulation layers or components, thereby maintaining volumetric efficiency while ensuring adequate electrical insulation for reliability.