Ironless Laminated Sheet Winding for High Density Motor Design
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Solution Overview
Problem
Conventional iron-cored motors are heavy and inefficient due to low packing densities and increased air gaps when coils are stacked, which is a concern for applications like aircraft where weight is critical, and they do not allow for efficient use of magnetic flux.
Innovation Solution
The development of an ironless core radial flux motor system using laminated sheet windings made from conductive materials like aluminum or copper, where stacked sheets are electrically connected in series to create a dense, thin conductor area with minimal air gaps, allowing for efficient magnetic flux interaction and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional iron-cored windings are used, then motors can be powerful and efficient, but the motors become heavy and have poor packing density
Solution Approach 1:
The patent removes the iron core from the motor winding structure, extracting the harmful weight component while maintaining the conductive path for magnetic flux interaction. The ironless core design eliminates the heavy ferromagnetic material that traditionally provided magnetic path continuity, replacing it with a lightweight alternative that achieves similar magnetic coupling through direct conductor exposure.
Solution Approach 2:
The patent employs composite construction by stacking multiple thin conductive sheets (such as aluminum or copper) to form the winding structure. These sheets are arranged and connected to create both mechanical strength and electrical continuity without requiring a solid iron core, achieving a composite material solution that balances structural integrity with weight reduction.
2Productivity
If coils are stacked together in conventional motors, then windings can be formed, but air gaps increase and packing density decreases
Solution Approach 1:
The patent implements a nested stacking arrangement where multiple conductor sheets are positioned one over another with precise alignment, creating a compact layered structure. The conductive sheets are nested within the stator or rotor assembly such that they maximize the use of available space, minimizing air gaps between adjacent windings and improving the overall packing density of the magnetic circuit.
Solution Approach 2:
The patent transitions from traditional three-dimensional coil winding to a two-dimensional sheet stacking approach. By laying down thin conductive sheets in parallel layers rather than wrapping volumetric coils, the design achieves better space utilization and reduced air gaps in the radial and axial dimensions, effectively using dimensional reconfiguration to improve packing efficiency.
3Force
If iron-cored configurations are used, then motors produce sufficient torque, but rotational inertia increases and responsiveness decreases
Solution Approach 1:
The patent extracts the heavy iron core that contributes to rotational inertia while maintaining the essential magnetic flux path through the use of stacked conductive sheets. By removing the ferromagnetic core material, the moment of inertia is significantly reduced, allowing the motor to accelerate and respond more quickly to control signals while still achieving adequate torque through the exposed conductor surfaces interacting with the magnetic field.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design results in a more efficient, lightweight motor with improved packing density and reduced air gaps, enhancing torque production and extending the lifespan of slip rings, while also reducing rotational inertia and increasing responsiveness.
Implementation Method 1
The stacked sheets are electrically connected in series to create a winding
Implementation Method 2
When rotated within a magnetic field or introduced to a rotating magnetic field, the resulting induction motor produces torque
Data Source
Figure 1A~1D
Figure 2A~2B
Figure 2C~2D
AI summary
Apparatuses, systems, and methods provide for high density laminated sheet windings in axial and radial flux configurations. According to embodiments described herein, motor components such as a rotor or stator include a number of stacked sheets (114) of conductive material. The stacked sheets (114) are electrically connected in series to create a winding. Each motor component includes a number of conductors (108) spaced apart with apertures between. The motor components are stacked and configured with the conductors (108) of one rotor or stator positioned within the apertures (110) of the other rotor or stator to create a thin, high density conductor. A magnetomotive force is created when the magnetic flux is positioned over the conductors (108).