Multilayer conductor design for flat wire motors is a method of using multiple layers of windings in the stator winding of a motor to increase the power density and efficiency of the motor.

The multilayer design of conductors involves winding the conductors in layers in the slots of the motor stator. Unlike single-layer windings, multilayer windings increase the number of conductors in a limited space, thereby increasing the number of turns and power output of the winding. The multi-layer conductor design allows for a higher fill factor. The fill factor is the percentage of stator slot space occupied by the conductors. By winding the conductor in multiple layers, the space in the stator slot can be utilized more efficiently, so the conductor occupies more space, thus increasing the fill factor.


The multilayer design of the conductor reduces the resistive losses. As the length of the conductor becomes longer due to multilayer winding, the total resistance of the conductor increases. However, by increasing the cross-sectional area of the conductor and reducing the length of the conductor, the resistance loss can be effectively reduced and the efficiency of the motor can be improved. Due to the use of multilayer windings, the total cross-sectional area of the wires increases, and the wires are subjected to a more uniform distribution of current. This reduces the temperature rise and current density of the wire, which in turn reduces resistance losses and heat generation.

Enameled wire is mainly used in the winding of flat wire motors. Enameled wire is used to make the stator windings, also known as stator coils, of electric motors. The stator coil is a winding fixed in the stator slot of the motor, which is energized by a current to produce a rotating magnetic field. Enameled wire insulation effectively insulates the electrical connections between the wires and between the wires and the stator slot, preventing short circuits and insulation breakage.