Abstract: A lightweight and efficient electrical machine element including a method of manufacture providing a stator winding for an electric machine which has a large portion of its volume containing electrically conductive strands and a small portion of its volume containing of an encapsulant material. The stator winding includes winding of a first phase by shaping a portion of a bundle of conductive strands into an overlapping, multi-layer arrangement. Winding of successive phases occurs with further bundles of conductor strands around the preceding phases constructed into similar overlapping, multi-layer arrangements. The multiple phases are impregnated with the encapsulant material using dies to press the bundles into a desired form while expelling excess encapsulant prior to the curing of the encapsulant material. The encapsulated winding is removed from the dies after the encapsulant has cured. The encapsulant coating on the strands may be activated using either heat or solvent.

Abstract: An axial flux brushless permanent magnet electrical machine having a stator and at least one rotor. The rotor includes a Halbach array of magnets with at least four magnets per magnetic cycle. The rotor magnets are contained within pockets in the rotor. The pockets are formed with magnet pocket walls being radial walls, active surface walls, and/or inactive surface walls where the walls retain the magnets within the pockets.

Abstract: An axial flux brushless permanent magnet electrical machine having a stator and at least one rotor. The rotor includes a Halbach array of magnets with at least four magnets per magnetic cycle. The rotor magnets are contained within pockets in the rotor. The pockets are formed with magnet pocket walls being radial walls, active surface walls, and/or inactive surface walls where the walls retain the magnets within the pockets.

Abstract: An axial flux brushless permanent magnet electrical machine having a stator and at least one rotor. The rotor includes a Halbach array of magnets with at least four magnets per magnetic cycle. The rotor magnets are contained within pockets in the rotor. The pockets are formed with magnet pocket walls being radial walls, active surface walls, and/or inactive surface walls where the walls retain the magnets within the pockets.

Abstract: A lightweight and efficient electrical machine element including a method of manufacture providing a stator winding for an electric machine which has a large portion of its volume containing electrically conductive strands and a small portion of its volume containing of an encapsulant material. The stator winding includes winding of a first phase by shaping a portion of a bundle of conductive strands into an overlapping, multi-layer arrangement. Winding of successive phases occurs with further bundles of conductor strands around the preceding phases constructed into similar overlapping, multi-layer arrangements. The multiple phases are impregnated with the encapsulant material using dies to press the bundles into a desired form while expelling excess encapsulant prior to the curing of the encapsulant material. The encapsulated winding is removed from the dies after the encapsulant has cured. The encapsulant coating on the strands may be activated using either heat or solvent.

Abstract: An axial flux brushless permanent magnet electrical machine having a stator and at least one rotor. The rotor includes a Halbach array of magnets with at least four magnets per magnetic cycle. The rotor magnets are contained within pockets in the rotor. The pockets are formed with magnet pocket walls being radial walls, active surface walls, and/or inactive surface walls where the walls retain the magnets within the pockets.