Continuous winding for electric motors

Abstract

A continuous winding for a motor that includes a winding block comprising a plurality of coils aligned together to form at least part of a motor winding, where each of the plurality of coils includes a left portion and a right portion that are offset from each other in spaced parallel planes, so that the plurality of coils aligned together are nested together, so that a portion of each of the plurality of coils aligned together supports a portion of an adjacent coil at least laterally and vertically, and a resin coating at least partially covers the winding block to positionally fix the aligned plurality of coils together.

What is claimed is: 
     
         1 . A continuous winding for a motor, comprising:
 a winding block comprising a plurality of coils aligned together to form at least part of a motor winding;   wherein each of the plurality of coils includes a left portion and a right portion that are offset from each other in spaced parallel planes, so that the plurality of coils aligned together are nested together,   wherein a portion of each of the nested together plurality of coils aligned together supports a portion of an adjacent coil at least laterally and vertically; and   a resin coating at least partially covers the winding block to positionally fix the nested together plurality of coils aligned together.   
     
     
         2 . The continuous winding according to  claim 1 , further comprising binders to physically bind together the nested together plurality of coils aligned together. 
     
     
         3 . The continuous winding according to  claim 1 , wherein each of the plurality of coils are insulated. 
     
     
         4 . The continuous winding according to  claim 1 , further comprising a second winding block comprising a second plurality of coils aligned together to form at least part of the motor winding;
 each of the second plurality of coils includes a left portion and a right portion that are offset from each other in parallel planes, so that the second plurality of coils aligned together are nested together,   wherein a portion of each of the nested together second plurality of coils aligned together supports a portion of an adjacent coil at least laterally and vertically; and   wherein the winding block and the second winding block are aligned together as at least part of the motor winding.   
     
     
         5 . The continuous winding according to  claim 4 , wherein the winding block and the second winding block are nested together so that one of the plurality of coils of the winding block is positioned adjacent to one of the plurality of second coils of the second winding block. 
     
     
         6 . The continuous winding according to  claim 5 , wherein the offset between the left portions and right portions in each of the plurality of coils is the same as the offset between the left portions and right portions in each of the second plurality of coils so that the one of the plurality of coils of the winding block supports the adjacent the one of the plurality of second coils of the second winding block at least vertically and laterally. 
     
     
         7 . The continuous winding according to  claim 5 , wherein the winding block and the second winding block are spaced to accommodate thermal expansion. 
     
     
         8 . The continuous winding of  claim 4 , wherein the winding block and the second winding block series coupled as a component of a linear motor. 
     
     
         9 . The continuous winding according to  claim 1 , wherein the resin comprises a polymer-based liquid that solidifies after being applied to the winding block. 
     
     
         10 . The continuous winding according to  claim 1 , wherein the resin coating insulates each of the plurality of coils of the winding block. 
     
     
         11 . The continuous winding according to  claim 1 , further comprising spacers to maintain a physical separation each of the plurality of coils of the winding block. 
     
     
         12 . A transportation system comprising:
 a transportation tube; and   the continuous winding of  claim 1  being arranged as a fixed component to cooperate with a rotor fixed to a pod that travels through the transportation tube.   
     
     
         13 . The transportation system of  claim 12 , wherein the transportation tube is a substantially vacuumed transportation tube. 
     
     
         14 . A method of forming continuous winding for a motor, comprising:
 aligning a plurality of coils together, wherein each of the plurality of coils includes a left portion and a right portion that are offset from each other in spaced parallel planes, so that the aligned plurality of coils are nested together so that a portion of each of the aligned plurality of coils nested together supports a portion of an adjacent coil at least laterally and vertically; and   applying a resin coating to the aligned plurality of coils nested together to positionally fix the aligned plurality of coils nested together to form a winding block.   
     
     
         15 . The method according to  claim 14 , further comprising:
 forming a second winding block by aligning a second plurality of coils together, wherein each of the second plurality of coils includes a left portion and a right portion that are offset from each other in spaced parallel planes, so that the aligned second plurality of coils are nested together so that a portion of each of the second aligned plurality of coils nested together supports a portion of an adjacent coil at least laterally and vertically;   applying a resin coating to the second aligned plurality of coils nested together to positionally fix the aligned plurality of coils nested together; and   nesting an end coil of the winding block and a second end coil of the second winding block together.   
     
     
         16 . The method according to  claim 15 , wherein a number of the plurality of coils in the winding block is the same as a number of the second plurality of coils in the second winding block. 
     
     
         17 . The method according to  claim 15 , wherein a number of the plurality of coils in the winding block is different from a number of the second plurality of coils in the second winding block. 
     
     
         18 . The method according to  claim 14 , further comprising:
 forming a second winding block by aligning a second plurality of coils together, wherein each of the second plurality of coils includes a left portion and a right portion that are offset from each other in spaced parallel planes, so that the aligned second plurality of coils are nested together so that a portion of each of the aligned second plurality of coils nested together supports a portion of an adjacent coil at least laterally and vertically;   applying a resin coating to aligned second plurality of coils nested together to positionally fix the aligned plurality of coils nested together;   installing at least one joint on the winding block and on the second winding block together; and   interconnecting the winding block and the second winding block via the at least one joint on at least one of the winding block and the second winding block.   
     
     
         19 . The method according to  claim 14 , further comprising, when aligning the plurality of coils, positioning spacers between adjacent coils. 
     
     
         20 . The method according to  claim 14 , further comprising, prior to applying the resin coating, binding the aligned plurality of coils nested together.