Multilayered coil structure

Claim 1

A cylindrically-shaped multilayered coil structure for use in coreless motors, comprising more than two coil sections each having a width equal to the circumference of the cylindrical coil structure divided by the number of coil sections, each coil section including at least inner and outer coil layers extending diagonally between opposite axial ends of the cylindrical coil structure, each such layer including a plurality of turns of a coil wire which extend diagonally completely around the circumference and forming an initial turn and a final turn, the initial and final turns of each outer layer being disposed adjacent to said initial and final turns, respectively, of the inner layer of the same coil section, each coil section including a crossing part interconnecting the final turn of the inner layer with the initial turn of the outer layer, each crossing part being of one integral piece and being continuous and unbroken from the final turn of the associated inner layer to the initial turn of the associated outer layer, each crossing part disposed axially inwardly of the axial end at which it is located, and being positioned in between the associated inner and outer layers.

Claim 5

A method of fabricating a cylindrically-shaped multilayered electrical coil for use in coreless motors, comprising the steps of: (A) forming an inner layer of a first of a plurality of coil sections, each said coil section including a plurality of turns of a coil wire extending diagonally between opposite axial ends of the cylindrically-shaped coil and along a portion of the circumference of the cylindrically-shaped coil, by winding a coil wire diagonally completely around the circumference for said plurality of turns such that said inner layer of said first coil section includes an initial turn and a final turn, said final turn terminating at either of said axial ends, (B) forming a first crossing part of said coil wire by extending said coil wire from a termination point of said final turn back to a location adjacent said initial turn at the same axial end as said termination point, said first crossing part being disposed inwardly of such axial end, (C) forming an outer layer of said first coil section upon the outer periphery of said inner layer of said first coil section and upon said first crossing part of extending said coil wire from a termination point of said first crossing part and winding said coil wire diagonally completely around the circumference for a plurality of turns, such that said outer layer of said first coil section includes initial and final turns disposed adjacent to said initial and final turns, respectively, of said inner layer, (D) forming an inner layer of a second coil section by extending said coil wire from said final turn of said outer layer and winding said coil wire diagonally completely around the circumference for a plurality of turns such that said inner layer of said second coil section includes an initial turn disposed adjacent to said final turn of said inner layer of said first coil section, and a final turn, the latter turn terminating at either of said axial ends, (E) forming a second crossing part of said coil wire by extending said coil wire from a termination point of said last-named final turn back to said initial turn of said inner layer of said second coil section at the same axial end as said last-named termination point, said second crossing part being disposed axially inwardly of each axial end, (F) forming an outer layer of said second coil section upon the outer periphery of said inner layer of said second coil section and upon said second crossing part by extending said coil wire from said second crossing part and winding said coil wire diagonally completely around the circumference for a plurality of turns, such that said outer layer of said second coil section includes initial and final turns disposed adjacent said initial and final turns, respectively, of said inner layer of said second coil section, and (G) continuing to form inner and outer layers of remaining coil sections such that inner and outer layers of a last coil section have final turns disposed adjacent the initial turns of said inner and outer layers, respectively, of said first coil section.

Claim 6

A method of fabricating a cylindrically-shaped multilayered electrical coil for use in coreless motors, comprising the steps of: (A) forming an inner layer of a first of a plurality of coil sections, each said coil section including a plurality of turns of a coil wire extending diagonally between opposite axial ends of the cylindrically-shaped coil and along a portion of the circumference of the cylindrically-shaped coil, by winding a coil wire diagonally completely around the circumference for said plurality of turns such that said inner layer of said first coil section includes an initial turn and a final turn, said final turn terminating at either of said axial ends, (B) forming a first crossing part of said coil wire by extending said coil wire from a termination point of said final turn back to a location adjacent said initial turn at the same axial end as said termination point, said first crossing part being disposed inwardly of such axial end, (C) forming an outer layer of said first coil section upon the outer periphery of said inner layer of said first coil section and upon said first crossing part of extending said coil wire from a termination point of said first crossing part and winding said coil wire diagonally completely around the circumference for a plurality of turns, such that said outer layer of said first coil section includes initial and final turns disposed adjacent to said initial and final turns, respectively, of said inner layer, (D) forming an inner layer of a second coil section by extending said coil wire from said final turn of said outer layer and winding said coil wire diagonally completely around the circumference for a plurality of turns such that said inner layer of said second coil section includes an initial turn disposed adjacent to said final turn of said inner layer of said first coil section, and a final turn, the latter turn terminating at either of said axial ends, (E) forming a second crossing part of said coil wire by extending said coil wire from a termination point of said last-named final turn back to said initial turn of said inner layer of said second coil section at the same axial end as said last-named termination point, said second crossing part being disposed axially inwardly of each axial end, (F) forming an outer layer of said second coil section upon the outer periphery of said inner layer of said second coil section and upon said second crossing part by extending said coil wire from said second crossing part and winding said coil wire diagonally completely around the circumference for a plurality of turns, such that said outer layer of said second coil section includes initial and final turns disposed adjacent said initial and final turns, respectively, of said inner layer of said second coil section, and (G) continuing to form inner and outer layers of remaining coil sections such that inner and outer layers of a last coil section have final turns disposed adjacent the initial turns of said inner and outer layers, respectively, of said first coil section.