Patent ID: 8261429

Claim:
A method of forming an axial gap dynamo electric machine, the method comprising the steps of: a) providing; i) an axle, ii) at least one rotor disk having at the periphery at least one circular array of permanent magnets with each magnet of said disk having an alternating orientation of the poles with respect to the adjacent magnets, iii) a plurality of arc shaped stator coil segments in which the stator windings form serpentine path in two parallel planes that are spaced apart by a gap and connected at the outer periphery of the arc so that each arc shaped segment has U-shaped radial cross-section, the gap between the two parallel planes being at least greater than the thickness of the at least one rotor disk, b) attaching the at least one rotor disk in rotary co-axle connection to said axle, c) inserting the two of more stator coils as adjacent segments around the periphery of the at least one rotor disk so that both of the connected serpentine winding straddle the rotor disk from opposite sides thereof, wherein the serpentine stator winding of the arc shaped stator coil segments in each of the two planes are spaced apart by a gap and are encapsulated in a dielectric thermally conductive medium.