Compressed motor winding
In one possible embodiment, a motor winding is provided having a high density multi-conductor wire bundle with a compacted Litz wire bundle. The compacted Litz wire bundle has a serpentine configuration with a central portion having compacted Litz wire and end turns having non-compacted Litz wire.
1. A motor winding comprising a high density multi-conductor wire bundle comprising a compacted Litz wire bundle comprising:
a) a serpentine configuration comprising a central portion and end turns; and
b) wherein the central portion comprises compacted Litz wire and wherein the end turns comprise non-compacted Litz wire such that voids between individual conductors within the compacted Litz wire in the central portion are smaller than voids between individual conductors within the non-compacted Litz wire in the end turns.
2. The motor winding of claim 1 , wherein the central portion extends in a plane and the end turns extend out of the plane.
3. The motor winding of claim 1 , wherein the central portion has a thickness and a width, and wherein the thickness of the central portion is less than the width of the central portion.
4. The motor winding of claim 3 , wherein the end turns have a thickness and a width, and wherein the thickness of the end turns are less than the width of the end turns.
5. The motor winding of claim 3 , wherein the thickness of the central portion is approximately 0.09 inches.
6. The motor winding of claim 5 , wherein the width of the central portion is about 0.425 inches or less.
7. The motor winding of claim 1 , wherein the multiple compacted Litz wire bundles are woven.
8. The motor winding of claim 1 , wherein the multiple compacted Litz wire bundles are layered.
9. The motor winding of claim 1 , wherein the multiple compacted Litz wire bundles are woven in layers.
10. The motor winding of claim 1 , wherein the motor winding is a stator winding.
11. The motor winding of claim 1 , wherein the winding is encased in a thermally conductive epoxy.
12. The motor winding of claim 11 , wherein the thermally conductive epoxy comprises boron nitride.
13. The motor winding of claim 11 , wherein the motor winding is laced together, and wherein the thermally conductive epoxy encases the laced motor winding.
14. A motor stator winding comprising a high density multi-conductor winding comprising multiple Litz wire bundles, each Litz wire bundle comprising a serpentine configuration with a compacted central portion and non-compacted end turns, the compacted central portion having a thickness and a width such that the thickness of the compacted central portion is less than the width of the compacted central portion, and wherein the multiple Litz wire bundles are at least one of: (a) woven; (b) layered; or (c) combinations thereof and encased in a thermally conductive epoxy.
15. The motor stator winding of claim 14 , wherein the thermally conductive epoxy comprises boron nitride.
16. The motor stator winding of claim 14 , wherein the each of the multiple Litz wire bundles comprises end turns, and wherein the compacted central portions are generally within a plane and wherein the end turns are out of the plane so as to minimize a thickness of the multiple Litz wire bundles in a central region of the stator.
17. The motor stator winding of claim 16 , wherein the non-compacted end turns have a thickness and a width, and wherein the thickness of the non-compacted end turns are less than the width of the non-compacted end turns.
18. The motor stator winding of claim 14 , wherein the thickness of the central portion is approximately 0.09 inches and the width of the central portion is about 0.425 inches or less.
19. The motor stator winding of claim 14 , wherein the multiple Litz wire bundles are stitched together.
20. A motor stator winding comprising a high density multi-conductor winding comprising multiple Litz wire bundles each comprising a serpentine configuration, each Litz wire bundle of the multiple Litz wire bundles comprising a compacted central portion and non-compacted end turns, and wherein the compacted central portion has a first thickness and a first width, and wherein the first thickness is less than the first width; and wherein the non-compacted end turns have a second thickness and a second width, and wherein the second thickness is less than the second width of the end turns, and wherein the multiple Litz wire bundles being at least one of:
(a) woven; (b) layered; or (c) combinations thereof, the multiple Litz wire bundles being laced together and encased in a thermally conductive epoxy.
21. The motor winding of claim 20 , wherein the multiple compacted Litz wire bundles are woven.
22. The motor winding of claim 20 , wherein the multiple compacted Litz wire bundles are layered.
23. The motor winding of claim 20 , wherein the multiple compacted Litz wire bundles are woven in layers.
24. The motor winding of claim 20 , wherein the thickness of the central portion is approximately 0.09 inches and the width of the central portion is about 0.425 inches or less.