Abstract: A method for forming a multiwire structure having two conductive wires insulated from and bonded to each other by insulating material includes applying a first fluid coating material to a first conductive wire. The first conductive wire bearing the first fluid coating material is advanced through a first die forming a first electrically insulated conductive wire comprising a solid layer of a first insulating material on the first conductive wire. A second conductive wire is provided adjacent to the first electrically insulated conductive wire, and a second fluid coating material is applied to the second conductive wire. The first electrically insulated conductive wire and the adjacent second conductive wire bearing the second fluid coating material are then advanced through a second die to form a multiwire structure having two conductive wires electrically insulated from each other and bonded to each other by the first and second insulating materials.

Abstract: A hairpin conductor includes two wire segments each having respective first and second ends and a respective middle region. The segments are disposed in a side-by-side orientation such that their first ends are proximate each other and their second ends are proximate each other. The first ends are welded to each other and the second ends are welded to each other, or the middle regions are welded to each other, thereby providing a welded wire assembly, which is bent such that the two wire segments are bent equally to form the hairpin conductor. The hairpin conductor has a primary bend in the middle regions to form an apex thereat and first and second secondary bends in the two wire segments nearer to the apex than to the first and second ends to form respective first and second shoulders thereat. A method of forming the hairpin conductor is also presented.

Abstract: A hairpin conductor includes two wire segments each having respective first and second ends and a respective middle region. The segments are disposed in a side-by-side orientation such that their first ends are proximate each other and their second ends are proximate each other. The first ends are welded to each other and the second ends are welded to each other, or the middle regions are welded to each other, thereby providing a welded wire assembly, which is bent such that the two wire segments are bent equally to form the hairpin conductor. The hairpin conductor has a primary bend in the middle regions to form an apex thereat and first and second secondary bends in the two wire segments nearer to the apex than to the first and second ends to form respective first and second shoulders thereat. A method of forming the hairpin conductor is also presented.