Abstract:
A device such a coil where each electrical conductors material are enclosed by a magnetic metals/materials in goal to all the magnetic field generated make a closed loop through a core, be amplified and oriented in wished direction. 
     The coil using this manufacturing method is destined to stators, rotors for axial, radial rotating or linear electric motors, transformers and all devices that generate a magnetic field (non-exhaustive list).

Description:
BACKGROUND OF THE INVENTION 
       [0001]    Conventional manufacturing method consists in winding or stacking wires or ribbons of an electrical conductor material around a core. Electric motors that use stators and rotors manufacturing with this method have an efficiency of 35-43% and mechanical, Jules effect and Eddy currents losses do not explained all. Other important losses must be considerate: 
         [0002]    The magnetic field does not make a closed loop through a core. 
         [0003]    Air gaps between wires/strands/core. 
         [0004]    Important part of the length of electrical conductor material (wire) it uses in turns and grows with the number of layers or windings strands. Only a small fraction of magnetic field is perpendicular to the core surface (especially in case of use of a round section wire). 
         [0005]    Proximity effect due to induce currents generated by the magnetic fields of adjacent conductor wire. 
         [0006]    Otherwise, this manufacturing method has other disadvantages: 
         [0007]    Impossible or very difficult to realize a bipolar coil with its poles N/S on wished side of the coil. 
         [0008]    The complex shapes are impossible to manufacture (need to have a constant section in case of ribbon winding). 
         [0009]    Slowly winding process due to the small space between cores and insulation injured risk. 
         [0010]    Cogging runs motor due to the stator and rotor teeth. 
       BRIEF SUMMARY OF THE INVENTION 
       [0011]    The disclosed invention solves these problems by a new manufacturing process when: 
         [0012]    Each single component of electrical structure (electrical main conductors disposed on rows and connecting end plates) is stacked alternately with a core segments and totally wrapped by this, without gaps (insulating or adhesive materials is not considered here) in goal that it&#39;s all magnetic field make a closed loop exclusively through the magnetic material of core segments. 
         [0013]    All the electrical main conductors connected together by plates, placed to opposite ends of them. (Plates could be in, but not necessary, same electrical conductor material). 
         [0014]    The goal is to reduce numbers of turns, and by placing a core segment on external faces of the plates, have a closer loop of their all magnetic field through a core. 
         [0015]    Depends on position of layers composed by the electric main conductors (vertical, horizontal, arc horizontal and axial or radial) and connecting end plates (up and down or opposite lateral faces) we can choice the magnetic pole faces. 
         [0016]    Wherein, on one face, two separate connecting ends plates are used and electric current (single phase) is apply IN/OUT on each of them, a dipolar coil could be create with the same possibility to choice the magnetic poles faces. 
         [0017]    Any complex coil shape could be create in respect of electrical and laws of magnetism: 
         [0018]    Total electrical resistance (R) of first group of electrical main conductors, connected by the first end plate must be equal to second group connected by the second end plate. 
         [0019]    The theoretical core volume attributed to the first group must be equal to core volume attributed to the second group. 
         [0020]    The dipolar coils is especially destined to use in Halbach arrays. 
         [0021]    Wherein, on opposite faces a single plate connect all the main conductors and electric current (single phase) is apply IN/OUT on each of them unipolar coil could be created. 
         [0022]    The unipolar coils are used in conventional disposition (serial connected). 
         [0023]    If necessary to redirect the magnetic field on precise coil face the position of electrical main conductor&#39;s layers must be in accordance with the core segments magnetic metals/materials orientation (grain oriented silicon steel, compounds of soft iron and dielectric resins with predominant magnetic direction not limitative list). 
         [0024]    Many different manufactures processes and metals/materials could be employing to realize the coil components (main conductors, connecting end plates, cores segments) and their assembling. (Please report to detailed description). 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0025]    Sheet  1 / 7   
           [0026]      FIG. 1 —illustrates a first coil model. 
           [0027]      FIG. 1A —exploded view of the coil shown in  FIG. 1 . 
           [0028]    Sheet  2 / 7   
           [0029]      FIG. 2  and cross-section H-H—illustrate the electric current flux and faces to be apply to obtain a dipolar coil. 
           [0030]      FIG. 2  A and cross-section J-J—illustrate the electric current flux and faces to be apply to obtain a single polar coil. 
           [0031]    Sheet  3 / 7   
           [0032]      FIG. 3 —illustrates a mechanical assembling process between electric conductor materials and connecting plate. 
           [0033]      FIG. 3A  and detail A—illustrate a key manufacture between electric conductor materials and connecting plate. 
           [0034]      FIG. 3B  and detail B—illustrate a different key manufacture between electric conductor materials and connecting plate. 
           [0035]    Sheet  4 / 7   
           [0036]      FIG. 4 —illustrates a second coil model. 
           [0037]      FIG. 4A —illustrates an exploded view of coil shown in  FIG. 4 . 
           [0038]      FIG. 4B —illustrates an assembly of six coils shown in  FIG. 4 . 
           [0039]    Sheet  5 / 7   
           [0040]      FIG. 5 —illustrates a third coil model. 
           [0041]      FIG. 5A —illustrates an exploded view of coil shown in  FIG. 5 . 
           [0042]      FIG. 5B —illustrates an exploded view of coil shown in  FIG. 5 . 
           [0043]    Sheet  6 / 7   
           [0044]      FIG. 6 —illustrates a fourth coil model. 
           [0045]      FIG. 6A —illustrates an exploded view of coil shown in  FIG. 6 . 
           [0046]      FIG. 6B —illustrates an exploded view of coil shown in  FIG. 6 . 
           [0047]    Sheet  7 / 7   
           [0048]      FIG. 7 —illustrates a fifth coil model. 
           [0049]      FIG. 8 —illustrates a ribbon composed by wires encapsulated by a magnetic metal/material core. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0050]    For clearer understanding references, numerals identify the same elements in all sheets and figures:
   Reference numeral  1 —Electrical main conductors.   Reference numeral  2 —Core segments.   Reference numeral  3 —Connect end plate.   Reference numeral  4  and  5 —Separate connect end plates.   
 
         [0055]    For a drawn simplification all the devices illustrated in sheets, figures have only four rows and core segments in necessaries numbers to encapsulate them, but in goal to reduce the Eddy current losses, their number must be as great as possible only the manufacturing processes and metals/materials properties can limit it. 
         [0056]    Electrical main conductors are organized in rows, composed by: 
         [0057]    Single (ribbon or metal/material sheet). 
         [0058]    Multiple shapes (ribbons or metal/material sheets). 
         [0059]    Single (cutouts could be made in goal to obtain a precise value of electric resistance R by sectional surface control). 
         [0060]    Multiples wires (unlimited cross-section shape). 
         [0061]    Different manufacture process can be employed to realize the electric main conductors and connecting end plates, depending on choice of metals/materials, components sizes and shapes. 
       First Method: 
       [0062]    When Cooper-Silver-Aluminum (no-limitative list) are used, complex shapes can be obtain by mechanical transformation (stamping-filled-forged-tooling-turning-grinding-press forming-cutting by Laser, plasma, water-jet, EDM process, etc.) on existing plates, ribbons or wires. 
         [0063]    Core segments must be beforehand electrically insulated. 
         [0064]    Electrical main conductors must be pasted (epoxy resins, adhesive films) first on core segments. 
         [0065]    Subs-assemble electrical main conductors-core segments pasted (epoxy resins, adhesive films) together in main coil core. 
         [0066]    Install the connecting end plates and fixed them by mechanical key (method shown in  FIG. 4 - FIG. 4A - FIG. 4B ). Glued with an electrical conductive resin or any welding process is also possible. 
         [0067]    Install the connecting end plates and core segments (epoxy resins, adhesive films). 
       Second Method: 
       [0068]    Core segments must be beforehand electrically insulated. 
         [0069]    Electrical main conductors by PCB process (etched from sheets of cooper, Silver, Aluminum no-exclusive list) laminated directly on core segments including connecting end plates segments. 
         [0070]    Subs-assemble electrical main conductors-core segments pasted (epoxy resins, adhesive films) together in main coil core. 
         [0071]    Assembling the connecting end plate sectors by welding process or glued with electrical conductive resins. 
       Third Method 
       [0072]    Core segments must be beforehand electrically insulated. 
         [0073]    Electrical main conductors make by 3D printing of an electrical ink (e.g. Silver ink, Graphene ink, Gold ink, no-exclusive list) directly on core segments. 
         [0074]    Subs-assemble electrical main conductors-core segments pasted (epoxy resins, adhesive films) together in main coil core. 
         [0075]    Connect end plates by 3D printing on lateral faces. 
         [0076]    Install the connecting end plates core segments (epoxy resins, adhesive films). 
       Fourth Method: 
       [0077]    Core segments must beforehand electrically insulated. 
         [0078]    Electrical main conductors and connected end plates by bonded an electrical compound (electrical conductive resin and electrical conductive powder metal, e.g. Cooper, Silver, Aluminum no-exclusive list) on final shape mold. 
         [0079]    Electrical main conductors must be pasted (epoxy resins, adhesive films) first on core segments. 
         [0080]    Subs-assemble electrical main conductors-core segments pasted (epoxy resins, adhesive films) together in main coil core. 
         [0081]    Install the connecting end plates and fix them by paste or glue with an electrical conductive resin. 
         [0082]    Install the connecting end plates core segments (epoxy resins, adhesive films). 
       Fifth Method: 
       [0083]    Core segments must be beforehand electrically insulated. 
         [0084]    Electrical main conductors and connect end plates by sintered electrical conductive powder metals (e.g. Silver, Cooper, Aluminum no-exclusive list) on final shape mold. 
         [0085]    Electrical main conductors must be pasted (epoxy resins, adhesive films) first on core segments. 
         [0086]    Subs-assemble electrical main conductors-core segments pasted (epoxy resins, adhesive films) together in main coil core. 
         [0087]    Install the connecting end plates and fix them by paste or glue with an electrical conductive resin. 
         [0088]    Install the connecting end plates core segments (epoxy resins, adhesive films). 
       Sixth Method: 
       [0089]    Core segments must beforehand electrically insulated. 
         [0090]    Electrical main conductors and connect end plates on electrical conductive powder metals (e.g. Silver, Cooper Aluminum no-exclusive list) by one of following (same family) process: 
         [0091]    EBM—Electron Beam Melting 
         [0092]    SLS—Selective Laser Sintering 
         [0093]    DMLS—Direct Metal Laser Sintering 
         [0094]    Electrical main conductors must be pasted (epoxy resins, adhesive films) first on core segments. 
         [0095]    Subs-assemble electrical main conductors-core segments pasted (epoxy resins, adhesive films) together in main coil core. 
         [0096]    Install the connecting end plates and fix them by paste or glue with an electrical conductive resin. 
         [0097]    Install the connecting end plates core segments (epoxy resins, adhesive films). 
       Seventh Method: 
       [0098]    Electrical main conductors, connect end plates, insulating stratum and core segments made by 3D printing machine provided with three printing heads, print alternately, but in a single operation. 
         [0099]    First head print with electrical compound. 
         [0100]    Second head print with an insulating resin. 
         [0101]    Third head print with a magnetic material compound. 
       Eighth Method: 
       [0102]    Core segments must beforehand electrically insulated. 
         [0103]    Electric main conductors made by electro-deposition of an electric metal/material (e.g. Cooper, Silver, no-exclusive list) directly on core segments. 
         [0104]    Subs-assemble electrical main conductors-core segments pasted (epoxy resins, adhesive films) together in main coil core. 
         [0105]    Connect end plates by electro-deposition on lateral faces. 
         [0106]    Install the connecting end plates core segments (epoxy resins, adhesive films). 
       Ninth Method: 
       [0107]    Core segments must beforehand electrically insulated. 
         [0108]    The core segments assembled in final core, as shown in  FIG. 4  without the electrical main conductors  FIG. 4  A ( 1 ) and connect end plates  FIG. 4  A ( 3 ) ( 4 ) and ( 5 ). Injection of, an electrical conductive compound, in the empty core cavities by using one of two electrical connecting holes  FIG. 4  ( 12 ) (the other one serve as venting). Before the injection process, the core assembly can be place in a mold or vise/nipper (optional) in goal to secure the operation when very high pressure is used. Main conductors and connect end plates can be realized in same mono-block structure. Individual coil can be manufactured or entire stators/rotors (x coils) including coils connectivity, can be product without any assembling/winding process. 
       Core Segments Manufacturing Methods 
       [0109]    Core segments can be manufacture in various methods and metals/materials. Due to reduced size of segments (they are only components of complete core) is easy to obtain laminations on wished direction when grain oriented silicon steel is used, or lamination on amorphous metals. Maximum ribbon width in general is 400 mm for grain oriented steel and 50 mm for amorphous metals. Staked lamination can be make plane or in arc without any form restriction (by mechanical transformation). 
         [0110]    All magnetic powder metals/material (amorphous metals-Iron-Silicon Iron-Phosphorous Iron-Iron Nickel, no-limitative list) and all manufacturing process (steel bonded-sintered metals-EBM-SLS-DMLS) can be used to realize the core segments without any form restriction. A particularly manufacture process is: bonded compound, in final shape mold, of amorphous metal powder and dielectric resin with predominant magnetic direction. 
         [0111]    In all assembling process with the electrical main conductors and connect end plate, electric insulation is required, preference is for epoxy resins, electrostatic paint, but all materials and process can be used (especially adhesive films if employed to connect the elements). 
         [0112]    Optional holes through the core segments could exist with any form or size restriction in goal to adjust the core volume (can be using as cooling system). 
         [0113]    A different manufacture process (extruding) can be employed to encapsulate a single wire or wires in ribbon array with a magnetic metal/material compound (compound with flexible or rigid resin depends on final destination). 
         [0114]    In this case, wires must be insulating first. 
         [0115]    Depends on position of layers composed by the electrical main conductors (vertical, horizontal, arc horizontal and axial or radial) and connecting end plates (up and down or opposite lateral faces) we can choice the magnetic pole faces. 
         [0116]    Wherein, on one face, two separate connecting ends plates are use, and electric current (single phase) is apply IN/OUT on each of them, a dipolar coil can be created with the same possibility to choice the magnetic poles faces. 
         [0117]    Any complex coil shape can be create in respect of electrical and laws of magnetism: 
         [0118]    Total electrical resistance (R) of first group of electrical main conductors connected by the first end plate must be equal to second group connected by the second end plate. 
         [0119]    The theoretical core volume attributed to the first group must be equal to core volume attributed to the second group. 
         [0120]    The dipolar coils is especially destined to use in Halbach arrays. 
         [0121]    When on opposite faces a single plate connect all the main conductors and electric current (single phase) is apply IN/OUT on each of them unipolar coil could be created. 
         [0122]    The unipolar coils are used in conventional disposition (serial connected). 
         [0123]    If needed to redirect the magnetic field on precise coil face the position of electrical main conductor&#39;s layers must be in accordance with the core segments magnetic metals/materials orientation (grain oriented silicon steel, compounds of soft iron and dielectric resins with predominant magnetic direction no-limitative list). 
       DETAILED DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
       [0124]      FIG. 1 —illustrates a complete coif with core segments of the main core disposed in vertical, radial, arc position and core segments of connect end plates. 
         [0125]      FIG. 1  A—exploded view of the coil shown in  FIG. 1  with: 
         [0126]    Four layers (eight wires/layers) of electrical main conductors ( 1 ) disposed in horizontal, axial and arc position. 
         [0127]    Eleven core segments ( 2 ). Nine for main core (seven+two identical) and two over the connect end plates. 
         [0128]    Connect end plates ( 3 )-( 4 )-( 5 ) placed on axial and vertical position. 
         [0129]    Optional holes for core volume adjustment ( 6 ) (could be use for a cooling system). 
         [0130]      FIG. 2 —cross-section H-H—illustrates the current flux (single phase) through electrical main conductors ( 1 ) and connect end plate ( 3 ) when is apply (IN) on connect end plate ( 4 ) and exit (OUT) by connect end plate ( 5 ), plus core sections ( 2 ) (dipolar configuration). 
         [0131]      FIG. 2A —cross-section J-J—illustrates the current flux (single phase) through electrical main conductors ( 1 ) and opposite connect end plates  3  when is apply (IN) and exit (OUT) plus core section ( 2 ) (unipolar configuration). 
         [0132]      FIG. 3 —illustrates an assembling process wherein the electrical main conductor ( 1 ) have a reduced cross-section zone ( 7 ), which will be passed through a hole ( 8 ) (with an adequate section) made on connect end plate ( 3 ). 
         [0133]      FIG. 3A —and detail A illustrate a fixed method (key) wherein exceeding zone ( 7 ) of main conductor ( 1 ) is blending ( 9 ) on top or below direction along the connect end plate ( 3 ). 
         [0134]      FIG. 3B  and detail B—illustrate a different fixed method (key) wherein exceeding zone ( 7 ) of electrical main conductor ( 1 ) is deformed by tapering ( 10 ) and looked against the connect ends plate. Another method, no-illustrates here is to twist the exceeding zone ( 7 ) of electrical main conductor ( 1 ) and looked against the connect ends plate. 
         [0135]      FIG. 4 —illustrates a complete coil with core segments of the main core disposed in horizontal, axial, arc position and core segments of connect end plates, with electrical connecting holes ( 12 ). 
         [0136]      FIG. 4  A—exploded view of the coil shown in  FIG. 4  with: 
         [0137]    Four layers (each one with a different ribbon number) of electrical main conductors ( 1 ) disposed in horizontal, axial and arc position. 
         [0138]    Seven core segments ( 2 ). Five for main core (all different in form and size) and two over the connect end plates. 
         [0139]    Connect end plates ( 3 )-( 4 )-( 5 ) placed on axial and vertical position. 
         [0140]      FIG. 4B —illustrates perspective view of a six coils assembly shown in  FIG. 4  and  FIG. 4A . 
         [0141]      FIG. 5 —illustrates a complete coil with core segments of the main core disposed in vertical, axial, position (core segments of connect end plates is not shown here). 
         [0142]      FIG. 5  A—exploded view of the coil shown in  FIG. 5  with: 
         [0143]    Four layers (single sheet) of electrical main conductors ( 1 ) disposed in vertical, axial and arc position. 
         [0144]    Five core segments ( 2 ). (all identical). 
         [0145]    Connect end plates ( 3 )-( 4 )-( 5 ) placed on axial (top and below) horizontal and arc position. 
         [0146]      FIG. 5B —illustrates a perspective view of a six coils assembly shown in  FIG. 5  and  FIG. 5A   
         [0147]      FIG. 6 —illustrates a complete coil with core segments of the main core disposed in vertical, radial and arc position (core segments of connect end plates are not shown here). 
         [0148]      FIG. 6  A—exploded view of the coil shown in  FIG. 6  with: 
         [0149]    Four rows (single sheet) of electrical main conductors ( 1 ) disposed in vertical, radial and arc position. 
         [0150]    Five core segments ( 2 ). (all identical). 
         [0151]    Connect end plates ( 3 )-( 4 )-( 5 ) placed on axial and vertical position  FIG. 6B —illustrates a perspective view of a six coils assembly shown in  FIG. 6  and  FIG. 6A . 
         [0152]      FIG. 7 -illustrates a different manufacturing process wherein two electrical main conductors ( 1 ) (single possible, not shown here) is sealed first on an electrically insulated magnetic metal/material and wind in goal to form a dipolar device (unipolar wherein single main conductor is used). 
         [0153]      FIG. 8 —illustrates a different realization wherein wires, utilized as electric main conductors ( 1 ) (with no-restriction on section form) encapsulated by a magnetic metal/material ( 2 ). 
         [0154]    Ribbon with twelve wires shown but numbers and different arrays could be used. Single wire encapsulate by a magnetic metals/material is possible. No-length limitation, device could be utilized in straight disposition or winded in no-limited modes and final shapes. 
         [0155]    Embodiments described above illustrate but do not limit this disclosure. It should also be understood that numerous modifications and variations are possible in accordance with the principles of present disclosure. Accordingly, the scope of this disclosure is defined only by the following claims.