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 stator winding comprising a high density multi-conductor winding comprising multiple Litz wire bundles each comprising a serpentine configuration with a compacted central portion and non-compacted end turns, and wherein the compacted central portion of a Litz wire bundle comprises individual jacketed conductors, and wherein the individual jacketed conductors are compressed so as to comprise reduced spacing between the individual jacketed conductor conductors, 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.
2. The motor stator winding of claim 1 , wherein the thermally conductive epoxy comprises boron nitride.
3. The motor stator winding of claim 1 , 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 turned out of the plane so as to minimize a thickness of the multiple Litz wire bundles in a central region of the stator.
4. The motor stator winding of claim 3 , 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.
5. The motor stator winding of claim 1 , wherein a thickness of the central portion is approximately 0.09 inches and a width of the central portion is about 0.425 inches or less.
6. The motor stator winding of claim 1 , wherein the multiple Litz wire bundles are stitched together.
7. A motor stator winding comprising a high density multi-conductor winding comprising multiple Litz wire bundles each comprising a serpentine configuration, each of the multiple Litz wire bundles comprising a compacted central portion and non-compacted end turns, wherein the compacted central portion of a Litz wire bundle comprises individual jacketed compressed conductors, the individual jacketed compressed conductors having a non-round cross section, 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.
8. The motor stator winding of claim 7 , wherein the thermally conductive epoxy comprises boron nitride.
9. The motor stator winding of claim 7 , 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 turned out of the plane so as to minimize a thickness of the multiple Litz wire bundles in a central region of the stator.
10. The motor stator winding of claim 9 , 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.
11. The motor stator winding of claim 7 , wherein a thickness of the central portion is approximately 0.09 inches and a width of the central portion is about 0.425 inches or less.
12. The motor stator winding of claim 7 , wherein the multiple Litz wire bundles are stitched together.