Abstract: A method for manufacturing a coil module for a stator for a tubular linear motor includes placing a plurality of bobbins and spacers on a winding mandrel and winding the plurality of bobbins with a single length of wire to form a set of coils. Three sets of such coils are interleaved on an encapsulation mandrel. A plurality of metal comb shaped elements, each including a longitudinal spine and a plurality of teeth are distributed about the circumference of the three interleaved sets of coils to form a coil module. The coil module and the mandrel are surrounded with an encapsulation mold. An encapsulating material is introduced into the encapsulation mold. The encapsulated coil module is removed from the encapsulating mold and the encapsulation mandrel after setting of the encapsulating material.

Abstract: A modular design for and method of constructing long stators for tubular electric linear motors having many sets of coils. In certain embodiments, the stator is made by assembling a multiplicity of identical coil modules which are combined to form a stator of whatever length may be required. In some embodiments, coil modules containing the coils are connected by intermediate connectors. In those embodiments, the sum of the effective length of the coil module and the effective length of the intermediate connector must be an integral multiple of the pole pitch of the magnets in the motor's mover. In some embodiments, longitudinal grooves are formed in the coil modules to provide paths for coolant.

Abstract: A method for manufacturing a coil module for a stator for a tubular linear motor includes placing a plurality of bobbins and spacers on a winding mandrel and winding the plurality of bobbins with a single length of wire to form a set of coils. Three sets of such coils are interleaved on an encapsulation mandrel. A plurality of metal comb shaped elements, each including a longitudinal spine and a plurality of teeth are distributed about the circumference of the three interleaved sets of coils to form a coil module. The coil module and the mandrel are surrounded with an encapsulation mold. An encapsulating material is introduced into the encapsulation mold. The encapsulated coil module is removed from the encapsulating mold and the encapsulation mandrel after setting of the encapsulating material.

Abstract: A modular design for and method of constructing long stators for tubular electric linear motors having many sets of coils. In certain embodiments, the stator is made by assembling a multiplicity of identical coil modules which are combined to form a stator of whatever length may be required. In some embodiments, coil modules containing the coils are connected by intermediate connectors. In those embodiments, the sum of the effective length of the coil module and the effective length of the intermediate connector must be an integral multiple of the pole pitch of the magnets in the motor's mover. In some embodiments, longitudinal grooves are formed in the coil modules to provide paths for coolant.