Helical coil design and process for direct fabrication from a conductive layer

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 structure having a tube-like shape relative to a reference axis extending through the shape, with a conductive material along an outer surface thereof;
• and
• creating a coil row about the reference axis by removing material from the surface with a tool according to an equation of the form:
• of
• X(θ)=[h/(2*π)]θ+ΣAnfi(nθ)
• wherein X is a coordinate is along the reference axis coil in an X, Y, Z coordinate system in which Y and Z are coordinates in a plane transverse to the reference axis, θ is the azimuth angle in the Y-Z plane, h is the turn to turn advance of the winding, An is a modulation amplitude of f1, herein, the tool thereby defining a variable or constant space width to provide a helical configuration wherein, along a series of different planes transverse to the reference axis the width of the conductor varies.

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 conductor positioned along a path of variable direction relative to a reference axis, the conductor having a groove formed therethrough of width Wg in accord with a center line defined by
• X(θ)=[h/(2*π)]θ±ΣAnf1(nθ)
• Y(θ)=Rf2(θ)
• Z(θ)=Rf3(θ)
• the conductor thereby providing at least a first coil row wherein X is a coordinate is along the reference axis coil, Y and Z are coordinates in a plane transverse to the reference axis, θ is the azimuth angle in the Y-Z plane, h is the turn to turn advance of the winding, An is a modulation amplitude of f1, and R is a measurable radius with respect to one or more surfaces of the winding, measured from the reference axis, the conductor having first and second opposing conductor surface regions each extending different distances R from the reference axis so that, at positions along the conductor path, portions of the first conductor surface region extend farther away from the reference axis than portions of the second conductor surface region,
• the conductor characterized at each of multiple different path positions by a cross sectional shape along a plane orthogonal to the path direction, the multiple cross sectional shapes varying among different path positions.

A method of forming a conductor assembly comprising:

• providing a plurality of conductive rows comprising a conductive layer;
• forming a groove through the conductive layer in each row to define a helical conductive path, wherein each groove extends beyond the helical path to define a line-in terminal and a line-out terminal in the conductive layer;
• positioning the conductive rows in a concentric configuration;
• and
• interconnecting line-in and line-out terminals of different conductive rows to provide a continuous current path among the different conductive rows in the assembly.