Patent ID: 9685264
Date: 2017-06-20
CPC Classifications: H01F,H02K,Y10T

Claim:
1. A method of producing a wound article from a strip of material, the wound article defining axial and radial directions, said method comprising: feeding a continuous strip of bulk material to a punch press; punching a plurality of winding slot cutouts into the bulk material to create a formed material; winding the formed material around itself such that a substantially cylindrical structure is created having a central opening with a central axis along the axial direction and bounded at its periphery by an innermost layer having at least one innermost winding slot cutout having an innermost cutout width, an outermost layer radially spaced from the innermost layer and having at least one outermost winding slot cutout having an outermost cutout width, and a main stator body including a plurality of intermediate layers between the innermost layer and the outermost layer, each of the plurality of intermediate layers having at least one intermediate winding slot cutout having an intermediate cutout width, the plurality of winding slot cutouts selectively aligned with one another to create at least one winding slot, wherein said step of punching a plurality of winding slot cutouts comprises punching a cutout having a first cutout width for intermediate radial layers of the wound formed material and a second cutout width for at least one of an radially innermost and radially outermost layers of the wound formed material, the second cutout width greater than the first cutout width such that at least one axial end of the winding slot approximates a rounded edge at a radial terminal end thereof; and winding a plurality of winding wires in the winding slot, the winding wires bent around and following the rounded edge of the winding slot.