Thermal-Sprayed Winding Head Assembly for Shorter Axial Length

The patent replaces the conventional mechanical bending and crimping process with a thermal spraying process. Conductors are sprayed onto the insulating base body in a molten or semi-molten state, allowing them to conform to the required geometry without mechanical deformation. This substitution eliminates the need for lengthy bending operations and reduces axial space requirements while maintaining the ability to create complex conductor shapes that fit into slots.

The patent changes the physical state of the conductor material during formation. Instead of using solid conductors that require mechanical bending, the conductors are applied in a molten or semi-molten state through thermal spraying. This parameter change allows the material to flow and conform to the desired shape, then solidifies in place, reducing the axial length required for the winding head formation process.

The patent replaces manual mechanical connection and insulation processes with automated thermal spraying. The thermal spray process simultaneously deposits conductor material and insulating material in a controlled sequence, eliminating manual assembly steps. This automation maintains manufacturing precision through computer-controlled spray deposition while dramatically increasing production speed and reducing labor requirements.

The patent performs preliminary action by pre-forming the insulating base body with integrated conductor pathways and support structures before applying the conductors. This preliminary preparation allows the thermal spray process to directly deposit conductors in their final positions without requiring subsequent manual assembly, insulation, or reinforcement steps, thereby increasing productivity while maintaining precision.

The patent replaces complex mechanical operations (bending, crimping, soldering) with thermal spraying to achieve different conductor geometries. The thermal spray process can deposit material in various patterns and shapes by controlling the spray gun movement, angle, and deposition parameters, eliminating the need for different mechanical processes for different geometries and reducing manufacturing complexity.

The patent makes the thermal spraying process universal for creating all conductor geometries. A single thermal spray system can produce various conductor shapes, sizes, and configurations by programming the spray deposition parameters, replacing the need for multiple specialized manufacturing processes and tools that would otherwise be required for different conductor designs.

The patent replaces mechanical bending and assembly processes with thermal spraying, which creates direct, continuous conductor deposits from the insulating base body to the connection points. This eliminates the need for additional conductor length required for mechanical bending and assembly operations, reducing ohmic losses while maintaining connection reliability through the direct thermal bond created during spraying.

The patent uses the insulating base body as an intermediary structure that integrates conductor support and connection functions. The base body provides built-in support structures and connection points that eliminate the need for separate mechanical assembly components, allowing conductors to be sprayed directly into their final positions with minimal excess length, thereby reducing ohmic losses while ensuring reliable connections.