CONDUCTOR WITH DIVOT FOR IMPROVED FORM FACTOR
A conductive element is provided and includes an electrically conductive material and a coating surrounding the electrically conductive material to form a coated member. The coated member is formed with a crown defined by bends in first and second transverse dimensions. The electrically conductive material is formed to define at least one divot proximate to the crown. The at least one divot is discernible through the coating.
1 . A conductive element, comprising:
an electrically conductive material; and
a coating surrounding the electrically conductive material to form a coated member,
the coated member being formed with a crown defined by bends in first and second transverse dimensions, and
the electrically conductive material being formed to define at least one divot proximate to the crown, the at least one divot being discernible through the coating.
2 . The conductive element according to claim 1 , wherein the conductive element comprises a high voltage hairpin (HVH) style conductor.
3 . The conductive element according to claim 1 , wherein the at least one divot has a radius of about 0.5 mm.
4 . The conductive element according to claim 1 , wherein the bends of the crown include a first bend in the first dimension and second and third opposite bends in the third dimension.
5 . The conductive element according to claim 1 , wherein the at least one divot is defined at an underside of the crown.
6 . The conductive element according to claim 1 , wherein the at least one divot is defined at an outer-side of the crown.
7 . The conductive element according to claim 1 , the electrically conductive material is formed to define:
a divot proximate to the crown at an underside of the crown, and
a divot proximate to the crown at an outer-side of the crown.
8 . An electro-dynamic machine, comprising:
a stator;
a rotor rotatably disposed in the stator; and
a plurality of conductive elements supportively disposed in the stator and receptive of current to drive rotation of the rotor,
each one of the plurality of conductive elements comprising:
an electrically conductive material; and
a coating surrounding the electrically conductive material and being formed with a crown defined by bends in first and second transverse dimensions,
the electrically conductive material being formed to define at least one divot proximate to the crown, the at least one divot being discernible through the coating.
9 . The electro-dynamic machine according to claim 8 , wherein the plurality of conductive elements is arranged in a two-deep circumferential array with the crowns disposed at one axial side of the stator.
10 . The electro-dynamic machine according to claim 8 , wherein each one of the plurality of conductive elements has about 1 mm of clearance from an adjacent one of the plurality of conductive elements.
11 . The electro-dynamic machine according to claim 8 , wherein each one of the plurality of conductive elements comprises a high voltage hairpin (HVH) style conductor.
12 . The electro-dynamic machine according to claim 8 , wherein each of the at least one divots has a radius of about 0.5 mm.
13 . The electro-dynamic machine according to claim 8 , wherein the bends of each of the crowns include a first bend in the first dimension and second and third opposite bends in the third dimension.
14 . The electro-dynamic machine according to claim 8 , wherein each of the at least one divots is defined at an interior of the crown.
15 . The electro-dynamic machine according to claim 8 , wherein each of the at least one divots is defined at an exterior of the crown.
16 . The electro-dynamic machine according to claim 8 , wherein the electrically conductive material is formed to define:
a divot proximate to the crown at an underside of the crown, and
a divot proximate to the crown at an outer-side of the crown.
17 . A method of fashioning a conductive element, comprising:
surrounding an electrically conductive material with a coating to form a coated member;
bending the coated member in first and second transverse dimensions to provide the coated member with a crown; and
defining at least one divot in the electrically conductive material proximate to the crown during the bending such that the at least one divot is discernible through the coating.
18 . The method according to claim 17 , wherein the bending comprises:
bending the coated member once in the first dimension to form a first bend; and
bending the coated member twice in opposite directions in the second dimension to form second and third bends, respectively.
19 . The method according to claim 18 , wherein the defining of the at least one divot is conducted during the bending of the coated member in the first dimension.
20 . The method according to claim 18 , wherein the defining comprises defining the at least one divot on one or both of an underside and an outer-side of the crown.