AeroVironment has patented a motor winding design with a high density multi-conductor wire bundle, featuring a compacted Litz wire bundle in a serpentine configuration. The central portion has compacted Litz wire, while end turns have non-compacted Litz wire. The compacted Litz wire is formed with high pressure press for improved performance. GlobalData’s report on AeroVironment gives a 360-degree view of the company including its patenting strategy. Buy the report here.

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According to GlobalData’s company profile on AeroVironment, Precision imaging drones was a key innovation area identified from patents. AeroVironment's grant share as of April 2024 was 50%. Grant share is based on the ratio of number of grants to total number of patents.

High density motor winding with compacted litz wire bundle

Source: United States Patent and Trademark Office (USPTO). Credit: AeroVironment Inc

A recently granted patent (Publication Number: US11942842B2) discloses a motor winding design that utilizes a high-density multi-conductor wire bundle, specifically a compacted Litz wire bundle. The winding features a unique serpentine configuration with a central portion comprising compacted Litz wire and end turns made of non-compacted Litz wire. The central portion undergoes a high-pressure press treatment to alter the cross-sectional shape of the individual jacketed conductors and reduce spacing between them, enhancing the efficiency of the winding.

Furthermore, the patent details a method for forming such a motor winding, involving compressing Litz wire to create a compacted Litz wire, shaping it into a serpentine winding with a central portion and end turns, and utilizing a press to compress only the central portion. Multiple bundles of compacted Litz wire can be combined through layering or weaving to form the winding, which can then be encased in a thermally conductive epoxy, potentially containing boron nitride. This innovative approach to motor winding design aims to improve performance and efficiency, offering a new solution for various applications requiring reliable and high-performance motors.

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GlobalData Patent Analytics tracks bibliographic data, legal events data, point in time patent ownerships, and backward and forward citations from global patenting offices. Textual analysis and official patent classifications are used to group patents into key thematic areas and link them to specific companies across the world’s largest industries.