Stator Assembly With Single-Turn Windings For High Conductor Fill

The patent divides the winding structure into discrete segments where each slot contains only 1-3 turns instead of many turns. This segmentation simplifies the winding process while maintaining motor performance through optimized conductor arrangement and interconnect technology.

The patent changes the fundamental parameter of turns per slot from many turns to 1-3 turns. This parameter change, combined with using wider conductors and optimizing the interconnect structure, maintains the required electrical characteristics while dramatically simplifying manufacturing.

By segmenting the winding into 1-3 turns per slot rather than many turns, the patent makes the winding process feasible for small motors. This segmentation allows standard manufacturing processes to be used even when motor size is reduced.

Instead of using thin wire with many turns to achieve required conductivity in small motors, the patent inverts the approach by using wider conductors with fewer turns (1-3 turns per slot). This inversion makes manufacturing easy while maintaining electrical performance in compact motor sizes.

The patent segments the winding into 1-3 turns per slot, which can be rapidly manufactured using automated processes. This segmentation maintains high conductor fill through optimized conductor width and arrangement while enabling fast production.

By changing the turns per slot parameter to 1-3 and adjusting conductor width accordingly, the patent achieves high conductor fill without labor-intensive winding. This parameter change enables automated manufacturing while maintaining optimal electrical characteristics.