Wiring Assembly And Method of Forming A Channel In A Wiring Assembly For Receiving Conductor and Providing Separate Regions of Conductor Contact With The Channel

Abstract

A conductor assembly and method for constructing an assembly of the type which, when conducting current, generates a magnetic field or which, in the presence of a changing magnetic field, induces a voltage. In one embodiment the method provides a first insulative layer tubular in shape and including a surface along which a conductor segment may be positioned. A channel formed in the surface of the insulative layer defines a first conductor path and includes a surface of first contour in cross section along a first plane transverse to the conductor path. A segment of conductor having a surface of second contour in cross section is positioned at least partly in the channel and extends along the conductor path. Along the first plane, contact between the conductor surface of second contour and the channel surface of first contour includes at least two separate regions of contact.

1 . A method for constructing a conductor assembly of the type which, when conducting current, generates a magnetic field or which, in the presence of a changing magnetic field, induces a voltage, comprising:
 providing a first insulative layer tubular in shape and including a surface along which a conductor segment may be positioned;   forming a channel in the surface of the insulative layer defining a first conductor path, the channel including a surface of first contour in cross section along a first plane transverse to the conductor path;   providing a segment of conductor, having a relatively large length dimension in proportion to a thickness measurable along a direction transverse to the length dimension, and having a surface of second contour in cross section along a plane transverse to the length dimension; and   positioning the segment of conductor at least partly in the channel with the length dimension extending along the conductor path wherein, along the first plane, contact between the conductor surface of second contour and the channel surface of first contour includes at least two separate regions of contact.   
   
   
       2 . The method of  claim 1  wherein:
 a portion of the conductor surface of second contour is characterized by a circular shape in cross section along a plane transverse to the conductor path; and   the channel surface of first contour includes one or more portions having a radius of curvature different from that of the circular shape.   
   
   
       3 . The method of  claim 2  wherein one of the portions of the channel surface having a radius of curvature different from that of a circular shape includes one or more relatively flat portions against which the circular shape is in contact. 
   
   
       4 . The method of  claim 3  wherein the channel surface of first contour includes at least two relatively flat portions against which the circular shape is in contact, and which are substantially parallel with one another and which are separated by a third relatively flat portion along the first contour. 
   
   
       5 . The method of  claim 1  wherein the channel surface of first contour includes at least three separate regions each in separate contact with the conductor surface of second contour. 
   
   
       6 . The method of  claim 5  wherein the channel surface of first contour has a rectangular-like shape with each separate region corresponding to one of three sides and an open portion of the channel corresponding to a fourth side of the shape. 
   
   
       7 . The method of  claim 5  wherein the channel surface of first contour has a dovetail-like shape. 
   
   
       8 . The method of  claim 1  wherein the channel surface includes a relatively flat portion extending along the conductor path, wherein along the conductor path an angle of the relatively flat channel surface portion, relative to an adjacent portion of the insulative layer surface into which the channel is formed, varies as a function of position along the path. 
   
   
       9 . The method of  claim 1  wherein the channel surface includes a relatively flat portion extending along the channel path, including one of the two separate regions of contact, wherein along multiple spaced-apart positions of the conductor path an angle of the relatively flat channel surface portion relative to an adjacent portion of the insulative layer surface into which the channel is formed is substantially invariant. 
   
   
       10 . The method of  claim 9  wherein a portion of the channel surface includes three relatively flat surfaces each generally positioned along a rectangular contour. 
   
   
       11 . The method of  claim 1  wherein one or more voids exist between the channel surface and the segment of conductor, one of the voids positioned between the two separate regions of contact. 
   
   
       12 . The method of  claim 11  wherein at least one cooling passage extends through the one or more voids so that coolant may come into direct contact with the segment of conductor. 
   
   
       13 . The method of  claim 1  wherein the segment of conductor is positioned entirely within the channel. 
   
   
       14 . The method of  claim 1  wherein the tubular shaped first insulative layer extends along an axis and is characterized by a circular shape in cross section where the cross section is along a plane transverse to the axis. 
   
   
       15 . The method of  claim 1  wherein the axis of the insulative layer follows a straight line. 
   
   
       16 . The method of  claim 1  wherein the tubular shape is formed about an axis of symmetry and the step of forming the channel includes defining the conductor path in a helical pattern about the axis. 
   
   
       17 . A conductor assembly of the type which, when conducting current, generates a magnetic field or which, in the presence of a changing magnetic field, induces a voltage, comprising:
 a layer having a surface of tubular shape with a channel formed therein, following a path about an axis, the channel characterized by a cross sectional shape along a plane passing transversely through a portion of the path; and   a conductive segment positioned in the channel and extending along the channel path, the segment having an outermost surface region positioned at least partly within the channel, with a first portion of the outermost surface region contacting the channel surface at a first location on the channel surface and a second portion of the outermost surface region contacting the channel surface at a second location on the channel surface, wherein:   a third portion of the outermost surface region of the conductive segment, positioned between the first and second portions, is spaced away from an area of the channel surface positioned between the first and second locations on the channel surface.   
   
   
       18 . The conductor assembly of  claim 17  wherein, with the third portion of the outermost surface region of the conductive segment spaced away from said area of the channel surface, a passage extends along the channel path between the third portion of the outermost surface region and said area of the channel surface. 
   
   
       19 . The assembly of  claim 18  wherein the passage extending along the channel path is suitable for flow of cooling fluid therethrough, which fluid may come into direct contact with the conductive segment. 
   
   
       20 . The conductor assembly of  claim 17  wherein the first and second locations are each relatively flat regions along the channel surface relative to the outermost surface region of the portion of the segment positioned in the channel. 
   
   
       21 . The conductor assembly of  claim 17  wherein the first location on the channel surface has a greater radius of curvature than that of the first portion of the outermost surface region of the conductive segment. 
   
   
       22 . The conductor assembly of  claim 17  wherein the channel has a V cross sectional shape about the plane passing transversely through said portion of the channel path, along which the first location is a first relatively flat region of the channel surface relative to the first portion of the conductor segment outermost surface region and the second location is a second relatively flat region of the channel surface relative to the second portion of the conductor segment outermost surface region. 
   
   
       23 . The assembly of  claim 22  wherein the first relatively flat region is along a first side of the V cross sectional shape, the second relatively flat region is along a second side of the V cross sectional shape and the third portion of the outermost surface region of the conductive segment is spaced-away from a region along the channel surface where the first and second sides of the V cross sectional shape meet. 
   
   
       24 . The conductor assembly of  claim 17  wherein the channel surface has a multi-sided cross sectional shape along and about the plane passing transversely through the portion of the channel path, and the third portion of the outermost surface region of the conductive segment is spaced-away from a region along the channel surface where two sides of the channel surface meet. 
   
   
       25 . The conductor assembly of  claim 17  wherein the channel has a dove tail cross sectional shape along the plane passing transversely through the portion of the channel path. 
   
   
       26 . The conductor assembly of  claim 17  wherein the channel has a three sided cross sectional shape about the plane passing transversely through the portion of the channel path. 
   
   
       27 . The conductor assembly of  claim 17  wherein the outermost surface region of the conductive segment has a circular cross sectional shape along and about the plane passing transversely through the portion of the channel path. 
   
   
       28 . The conductor assembly of  claim 17  wherein the conductive segment is positioned entirely within the channel. 
   
   
       29 . The method of  claim 1  wherein the channel surface of first contour includes a lower surface having first and second distinct surface portions,
 a first one of the surface portions extending a maximum distance from the layer surface, and   a second one of the surface portions, adjoining the first one, extending a greater distance from the layer surface than the first maximum distance, transition between the first and second surface portions characterized by an abrupt change in radius of curvature.   
   
   
       30 . The method of  claim 29  wherein transition between first and second surface portions is characterized by a corner. 
   
   
       31 . The method of  claim 1  wherein the channel surface of first contour includes a lower surface having first and second distinct surface portions:
 a first one of the surface portions having a circular, a U shape or a quadrilateral-like profile and extending a maximum distance from the layer surface; and   a second one of the surface portions, adjoining the first one, having a V shape, a circular, a U shape or a quadrilateral-like profile extending a greater distance from the layer surface than said maximum distance.   
   
   
       32 . The method of  claim 31  wherein the transition between the first and second surface portions is characterized by a corner profile. 
   
   
       32 . The assembly of  claim 17  wherein the conductive segment is a multistranded conductor.