Method of making densely-packed electrical conductors

Electric heating – Metal heating – By arc

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Details

21912185, 36447408, 427555, 427116, 29598, B23K 2612

Patent

active

055759327

ABSTRACT:
Windings for an electric motor are formed by depositing successive layers of conductive material and etching into the conductive material with a precisely-controlled high-energy beam. A computer stores information on the exact structure of the monolith of windings to be built, in the form of a series of successive planar cross-sections of the monolith. In making the monolith, one deposits a layer of conductive material onto a workpiece, bonds the conductive material to the workpiece, and cuts a pattern into the layer, using a high-energy beam in the presence of an oxidizing atmosphere. The beam causes the formation of electrically-insulating oxides which separate the layer into distinct conductive regions, according to a pattern defined by one of the stored cross-sections. In an alternative, one can also inject additional insulating material into the cuts formed by the beam. The monolith is thus built up, layer by layer, in a series of iterations. No actual wire is ever used, and the result is a monolith having conductors equivalent to windings which occupy a large percentage of the available cross-sectional area.

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