Wave Winding Armature

Abstract

An armature for an electromotive device having a unitary coil and armature is disclosed. The armature may include a coil having inner and outer wave winding portions separated by an insulator, each of the wave winding portions comprising a plurality of sheet metal conductors, and a commutator having a plurality of sheet metal commutator segments each being integrally formed with one of the conductors. The armature may be fabricated from a pair of conductive sheets by forming in each of the conductive sheets a plurality of conductive bands each having first and second conductor portions, shaping the conductive sheets into inner and outer cylinders, positioning the inner cylindrical conductive sheet inside the outer cylindrical conductive sheet, forming a coil from the first conductor portions of the inner and outer cylindrical conductive sheets, and forming a commutator from the second conductor portions of the inner and outer cylindrical conductive sheets.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the teachings disclosed herein are illustrated by way of example, and not by way of limitation, in the accompanying drawings in which like reference numerals refer to similar elements wherein:

FIGS. 1A and 1B are graphical illustrations exhibiting a plan view of a pair of copper plates, precision cut for use in a brushless motor;

FIG. 2 is a graphical illustration of an elevation perspective view of the copper plate of FIG. 1A rolled into a hollow cylinder for use in a motor;

FIG. 3 is a graphical illustration of an elevation perspective view of the copper plate of FIG. 1B rolled into a hollow cylinder for use in a motor;

FIG. 4 is a graphical illustration of an elevation perspective view of the cylinder of FIG. 2 being inserted into the cylinder of FIG. 3 to form a cylindrical conductive coil for use in a motor;

FIG. 4A is a graphical illustration of an enlargement of a portion of FIG. 4 illustrating detail of a wound glass fiber layer;

FIG. 5 is a schematic illustration of a conductive lap winding to form a continuous cylindrical conductive coil for use in a motor;

FIG. 5A is a graphical illustration of a conductive wave winding to form one phase of a continuous cylindrical conductive coil for use in a motor;

FIG. 5B illustrates a series of connection pads in a portion of a conductive wave winding;

FIG. 5C illustrates connection features in a portion of a conductive wave winding;

FIG. 5D illustrates additional connection features in a portion of a conductive wave winding;

FIG. 5E illustrates a series of lap windings forming spaced phase loops in a prior art conductive coil;

FIG. 6 is a plan view of a commutator;

FIG. 6A is a plan view of an alternative commutator;

FIG. 7 is an exploded perspective view of an ironless core armature with flywheel inserted and a commutator electrically connected to the conductive coil;

FIG. 7A is an exploded perspective view of an ironless core armature with drive shaft and flywheel inserted and an alternative commutator electrically connected to the conductive coil;

FIG. 8 is a perspective view of an assembled ironless core armature with drive shaft and flywheel inserted and a commutator electrically connected to the conductive coil; and

FIG. 8A is a perspective view of an assembled ironless core armature with drive shaft and flywheel inserted and an alternative commutator electrically connected to the conductive coil.

Claims

1. An inductive coil for an electromotive device, comprising: a pair of concentric inner and outer sheet metal winding portions, each of the winding portions comprising a plurality of parallel linear conductive bands with each of the conductive bands of one of the winding portions being coupled to one of the conductive bands of the other winding portion to form a continuous coil.

2. The inductive coil of claim 1 wherein the inner and outer sheet metal winding portions are separated by a continuous non-conductive fiber extending around the circumference of the inner winding portion a plurality of times to form an insulation portion.

3. The inductive coil of claim 2 further comprising an encapsulation material that impregnates the winding portions and the insulation layer.

4. The conductive coil of claim 2 wherein the continuous non-conductive fiber strand comprises glass.

5. The conductive coil of claim 3 wherein the encapsulation material comprises polyimide.

6. The inductive coil of claim 1 wherein each of the winding portions comprises precision machined and rolled copper.

7. An electromotive device comprising: an armature having a plurality of inductive coils wherein each inductive coil comprises a pair of concentric inner and outer sheet metal winding portions, each of the winding portions comprising a plurality of parallel linear conductive bands with each of the conductive bands of one of the winding portions being coupled to one of the conductive bands of the other winding portion to form a continuous coil; andwherein each of the plurality of inductive coils comprises a first end and a second end, and wherein each first end is electrically connected to a power source and each second is electrically connected to every other second end.

8. The electromotive device of claim 7 wherein the inner and outer sheet metal winding portions are separated by a continuous non-conductive fiber extending around the circumference of the inner winding portion a plurality of times to form an insulation portion.

9. The electromotive device of claim 8 further comprising an encapsulation material that impregnates the winding portions and the insulation layer.

10. The electromotive device of claim 7 wherein the electrically connected second ends of the plurality of inductive coils comprise a neutral connection.

11. The electromotive device of claim 7 wherein the first ends of each of the plurality of inductive coils are arranged within a radial distance of about 90° around the circumference of the armature.

12. The electromotive device of claim 8 wherein the continuous non-conductive fiber strand comprises glass.

13. The electromotive device of claim 9 wherein the encapsulation material comprises polyimide.

14. The electromotive device of claim 7 wherein each of the winding portions comprises precision machined and rolled copper.

15. An inductive coil for an electromotive device, comprising: a pair of concentric inner and outer sheet metal winding portions, each of the winding portions comprising a plurality of conductive bands each having a first end and a second end offset from the first end by a radial distance about the coil, with each of the conductive bands of one of the winding portions being coupled to one of the conductive bands of the other winding portion.

16. The inductive coil of claim 15 wherein the radial distance is about 90°.

17. The inductive coil of claim 15 wherein the inner and outer sheet metal winding portions are separated by a continuous non-conductive fiber extending around the circumference of the inner winding portion a plurality of times to form an insulation portion.

18. The inductive coil of claim 17 further comprising an encapsulation material that impregnates the winding portions and the insulation layer.

19. The conductive coil of claim 17 wherein the continuous non-conductive fiber strand comprises glass.

20. The conductive coil of claim 17 wherein the encapsulation material comprises polyimide.

21. The inductive coil of claim 15 wherein each of the winding portions comprises precision machined and rolled copper.

22. An inductive coil for an electromotive device, comprising: a pair of concentric inner and outer sheet metal winding portions, each of the winding portions comprising a plurality of conductive bands each extending from a first end to a second end in a single radial direction, with each of the conductive bands of one of the winding portions being coupled to one of the conductive bands of the other winding portion.

23. The inductive coil of claim 22 wherein the inner and outer sheet metal winding portions are separated by a continuous non-conductive fiber extending around the circumference of the inner winding portion a plurality of times to form an insulation portion.

24. The inductive coil of claim 23 further comprising an encapsulation material that impregnates the winding portions and the insulation layer.

25. The conductive coil of claim 23 wherein the continuous non-conductive fiber strand comprises glass.

26. The conductive coil of claim 24 wherein the encapsulation material comprises polyimide.

27. The inductive coil of claim 22 wherein each of the winding portions comprises precision machined and rolled copper.