Abstract: An insulated coil for use in a coil and pole assembly comprising an electrically conductive coil including a plurality of aligned, overlapping turns that are coated with a powder coating material so as to be electrically insulated from each other. The powder coated coil is heated so as to partially cure the powder coating material and then fitted about its associated pole. Once disposed about the pole, the coil is compressed in the vertical and horizontal directions, and heated while in the compressed state to completely cure the powder coating material.

Abstract: A bobbin for insulating a coil including a base portion comprising an electrically insulative material having an inner surface, an outer surface, an outer periphery, and a pole opening (54). An inner flange extends outwardly from the base portion in a first direction from the pole opening and at least partially defines the pole opening. Moreover, an outer flange extends outwardly from the base portion in the first direction from the outer periphery of the base portion. With this configuration, the bobbin is sized and configured to be placed on a side of the coil to provide ground insulation thereto.

Abstract: A particular coil configuration for an armature coil for a motor is disclosed, wherein a single-turn armature coil is preferably comprised of eight individual parallel conductors electrically insulated from each other and arranged to have a rectangular cross-section, wherein the eight conductors are split into two groups of four conductors to form an air gap at the loop portion of the coil. This "split-loop" armature coil configuration provides a greater cooling surface area for the armature coils at a hot spot of the coil, thereby reducing the hot spot temperature and increasing the current capability of the machine. Moreover, the split-loop armature coil configuration avoids the problem of shorted turns between the individual conductors and thus increases the reliability of the machine.