Multi-Layer Flat Wire Coil Winding with Auxiliary Core
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Solution Overview
Problem
The assembly of multi-layer flat wire coils is challenging due to tight mechanical tolerances and the risk of electrical discharges between layers, and the process of winding multiple layers is complex and prone to errors, especially when optimizing the fill factor for improved thermal conductivity and reduced thermal resistance.
Innovation Solution
A method for winding dual-layer and multi-layer flat wire coils that involves using auxiliary and winding cores to efficiently manage wire placement, with optional clamping and rotation steps to form layers without the need for extra space for terminals, and the use of insulating foils to prevent electrical discharges, allowing for a compact and bonded coil structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple single-layer coils are assembled together to form multi-layer coils, then the thermal conductivity can be improved, but the assembly complexity increases and mechanical tolerances become tighter
Solution Approach 1:
The patent combines multiple layers of flat wire windings into a single integrated coil structure during the winding process, rather than assembling separate single-layer coils. This merging approach maintains the thermal conductivity benefits of multi-layer construction while eliminating the assembly complexity and tight mechanical tolerance requirements that would result from joining multiple separate coils.
Solution Approach 2:
The patent performs the multi-layer winding operation in a single continuous process before the coil is installed in the motor. By pre-forming the complete multi-layer structure during manufacturing, the complex assembly operations are eliminated, and the coil can be installed as a single unit, reducing both assembly complexity and mechanical tolerance requirements.
2Temperature
If the fill factor is increased to reduce thermal resistance, then the thermal performance improves, but the risk of electrical discharges between layers increases
Solution Approach 1:
The patent introduces insulating foils as intermediary layers between adjacent windings within the multi-layer structure. These foils maintain close spacing between layers (preserving low thermal resistance and high fill factor) while providing electrical insulation to prevent discharges. The insulating foils act as mediators that enable both thermal efficiency and electrical safety simultaneously.
3Temperature
If rectangular wire with high aspect ratio is used to improve fill factor, then the thermal conductivity increases, but the manufacturing precision requirements become tighter
Solution Approach 1:
The patent segments the winding process into controlled stages using auxiliary and winding cores, which allows for precise placement of each layer without requiring extremely tight tolerances on the wire dimensions themselves. The segmentation of the winding process into manageable operations compensates for the tight mechanical tolerances inherent in using high aspect ratio rectangular wire.
4Ease of manufacture
If a single-layer flat wire coil is used, then the assembly is simpler, but the thermal conductivity is reduced compared to multi-layer configurations
Solution Approach 1:
The patent merges multiple layers of windings into a single integrated coil structure through a unified winding process. This approach captures the thermal conductivity advantages of multi-layer construction (by creating true multi-layer density) while maintaining assembly simplicity (by producing one integrated piece rather than multiple separate components that would require assembly).
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 method enables the production of compact, high-performance flat wire coils with improved thermal conductivity and reduced risk of electrical discharges, facilitating tighter mechanical tolerances and simpler assembly with fewer process steps, thus enhancing the motor's continuous force output and reliability.
Implementation Method 1
The wire to be used comprises a conductive core and an insulating jacket
Implementation Method 2
The electric core conducts heat well
Implementation Method 3
the insulator conducts heat rather poorly
Data Source
AI summary
The present invention is related to a method for winding a dual-layer flat wire coil, and to method for winding a multi-layer flat wire coil. Furthermore, the present invention is related to a device for winding such coils and to a dual-layer flat wire coil and to a multi-layer flat wire coil obtainable by performing the method of the present invention. Finally, the invention is related to a linear motor comprising such a dual-layer flat wire coil and/or multi-layer flat wire coil. According to the invention, an auxiliary winding core is used to temporarily store wire that is intended to form the odd layer of any pair of layers in the multi-layer coil.