Abstract: A method for applying varnish to a stator of an electric motor includes depositing varnish onto an outer laminate of the stator, accumulating the deposited varnish with a ridge on the outer laminate, and directing the accumulated varnish into a slot of the outer laminate with the ridge.

Abstract: A vehicle power module assembly including first and second power modules is provided. The first power module may include a first lock feature extending from a lower portion of a first minor side at a first central axis. The second power module may include a second lock feature at an upper portion of a second minor side at a second central axis. The lock features may be sized for interlock with one another to secure the power modules to one another. The first lock feature may be a loop element defining a through-hole and the second lock feature may be a wedge. The through-hole may be sized for the wedge to extend therein and to interlock the first power module and the second power module to one another. The first lock feature may be a flexible hook element and the second lock feature may be a slot.

Abstract: An electric machine includes a stator core having an outer circumferential surface, an inner circumferential surface, and longitudinal slots recessed into the inner circumferential surface. Each of the slots has first and second radial walls, an outboard circumferential wall extending between the radial walls, an entrance portion having opposing first and second angled walls extending divergently away from the inner circumferential surface, a first shoulder connecting the first radial wall to the first angled wall, and a second shoulder connecting the second radial wall to the second angled wall. Windings are disposed in the slots. Slot liners are also disposed in the slots such that the windings are disposed in an interior of the slot liners.

Abstract: A motor includes a stator core and a stator booster. The stator booster includes a booster back-iron and a plurality of booster teeth. The booster back-iron includes a first end surface that abuts a first end surface of the stator core's back-iron for electrical communication therewith. The booster teeth extend radially inward from the booster back-iron and are spaced apart from one another in a circumferential direction about the central axis to define a plurality of booster slots that align with slots of the stator core. A first end surface of each booster tooth abuts a first end surface of a corresponding tooth of the stator core for electrical communication therewith. An electrically insulating material encapsulates opposite sides of each booster tooth that define the booster slots and a second end surface of each booster tooth that is opposite the first end surface of that booster tooth.

Abstract: A vehicle includes a battery, an electric machine, a thermistor, and a controller. The electric machine is configured to draw electrical power from the battery to propel the vehicle. The electric machine has a rotor and a stator. The stator has a core, interconnected hairpins, and a neutral bar. The core defines slots. The interconnected hairpin windings are arranged within the slots and are arranged to form a plurality of electrical phases. The neutral bar is connected to each of the electrical phases and defines an orifice. The thermistor is disposed within the orifice and is configured to sense a temperature of the electric machine. The controller is programmed to control a power output of the electric machine based on the temperature of the electric machine.

Abstract: A laminate for a stator core, the laminate includes an annular body defining an inner edge, a plurality of wire slots extending radially outward from the inner edge, and a containment zone disposed radially outward of the plurality of wire slots. The containment zone is configured to contain fluid applied radially outward from the plurality of wire slots.

Abstract: A vehicle power module assembly including first and second power modules is provided. The first power module may include a first lock feature extending from a lower portion of a first minor side at a first central axis. The second power module may include a second lock feature at an upper portion of a second minor side at a second central axis. The lock features may be sized for interlock with one another to secure the power modules to one another. The first lock feature may be a loop element defining a through-hole and the second lock feature may be a wedge. The through-hole may be sized for the wedge to extend therein and to interlock the first power module and the second power module to one another. The first lock feature may be a flexible hook element and the second lock feature may be a slot.

Abstract: A method for applying varnish to a stator of an electric motor includes depositing varnish onto an outer laminate of the stator, accumulating the deposited varnish with a ridge on the outer laminate, and directing the accumulated varnish into a slot of the outer laminate with the ridge.

Abstract: A vehicle power module assembly including first and second power modules is provided. The first power module may include a first lock feature extending from a lower portion of a first minor side at a first central axis. The second power module may include a second lock feature at an upper portion of a second minor side at a second central axis. The lock features may be sized for interlock with one another to secure the power modules to one another. The first lock feature may be a loop element defining a through-hole and the second lock feature may be a wedge. The through-hole may be sized for the wedge to extend therein and to interlock the first power module and the second power module to one another. The first lock feature may be a flexible hook element and the second lock feature may be a slot.

Abstract: An electric machine includes windings, a terminal block, and terminal connectors. The windings have lead ends and neutral ends. The terminal block has a plurality of bus bars, a neutral bar, and an insulating material. Each bus bar is connected to one or more of the lead ends. The neutral bar is connected to one or more of the neutral ends. The insulating material encapsulates the plurality of bus bars and the neutral bar, defines a plurality of orifices, and defines a plurality of slots. Each lead end extends through one of the orifices from the outer boundary to one of the bus bars. Each neutral end extends through one of the orifices from the outer boundary to neutral bar. Each terminal connector extends through one of the slots from the outer boundary to one of the bus bars.

Abstract: A vehicle, electric machine, and stator include stator teeth extending from a yoke portion toward a rotor and defining slots between adjacent teeth with windings positioned within the slots, wherein the teeth form pockets at connections to the yoke portion. Electrically insulating slot paper may line at least three sides of the slots. The pockets may extend into the teeth or the yoke portion where the teeth extend from the yoke portion, and may be filled with an electrically insulating compound that secures the insulating slot paper lining and electrically conductive rectangular windings within the slots.

Abstract: A vehicle includes a battery, an electric machine, a thermistor, and a controller. The electric machine is configured to draw electrical power from the battery to propel the vehicle. The electric machine has a rotor and a stator. The stator has a core defining a plurality of slots and windings arranged within the slots. The thermistor is disposed within a first of the slots between first and second axial ends of the core and is configured to measure a temperature of the electric machine. The controller is programmed to control a power output of the electric machine based on the temperature of the electric machine.

Abstract: A vehicle includes a battery, an electric machine, a thermistor, and a controller. The electric machine is configured to draw electrical power from the battery to propel the vehicle. The electric machine has a rotor and a stator. The stator has a core, interconnected hairpins, and a neutral bar. The core defines slots. The interconnected hairpin windings are arranged within the slots and are arranged to form a plurality of electrical phases. The neutral bar is connected to each of the electrical phases and defines an orifice. The thermistor is disposed within the orifice and is configured to sense a temperature of the electric machine. The controller is programmed to control a power output of the electric machine based on the temperature of the electric machine.

Abstract: A vehicle includes a battery, an electric machine, a thermistor, and a controller. The electric machine is configured to draw electrical power from the battery to propel the vehicle. The electric machine has a rotor and a stator. The stator has a core defining a plurality of slots and windings arranged within the slots. The thermistor is disposed within a first of the slots between first and second axial ends of the core and is configured to measure a temperature of the electric machine. The controller is programmed to control a power output of the electric machine based on the temperature of the electric machine.

Abstract: A vehicle, electric machine, and stator include stator teeth extending from a yoke portion toward a rotor and defining slots between adjacent teeth with windings positioned within the slots, wherein the teeth form pockets at connections to the yoke portion. Electrically insulating slot paper may line at least three sides of the slots. The pockets may extend into the teeth or the yoke portion where the teeth extend from the yoke portion, and may be filled with an electrically insulating compound that secures the insulating slot paper lining and electrically conductive rectangular windings within the slots.

Abstract: A vehicle power module assembly including first and second power modules is provided. The first power module may include a first lock feature extending from a lower portion of a first minor side at a first central axis. The second power module may include a second lock feature at an upper portion of a second minor side at a second central axis. The lock features may be sized for interlock with one another to secure the power modules to one another. The first lock feature may be a loop element defining a through-hole and the second lock feature may be a wedge. The through-hole may be sized for the wedge to extend therein and to interlock the first power module and the second power module to one another. The first lock feature may be a flexible hook element and the second lock feature may be a slot.

Abstract: A vehicle power module assembly including first and second power modules is provided. The first power module may include a first lock feature extending from a lower portion of a first minor side at a first central axis. The second power module may include a second lock feature at an upper portion of a second minor side at a second central axis. The lock features may be sized for interlock with one another to secure the power modules to one another. The first lock feature may be a loop element defining a through-hole and the second lock feature may be a wedge. The through-hole may be sized for the wedge to extend therein and to interlock the first power module and the second power module to one another. The first lock feature may be a flexible hook element and the second lock feature may be a slot.

Abstract: An electric vehicle power supply includes a housing, a power supply, and a plurality of fasteners. The housing defines an internal cavity and has inwardly protruding tabs that extend into the cavity. The power assembly has a front cover and an end cover. The power assembly also has an array of electrical switching units arranged horizontally between the front and end covers. The front and end covers have outwardly protruding tabs. Each of the plurality of fasteners extend vertically, engage one inwardly protruding tab, and engage one outwardly protruding tab to secure the power assembly to the housing.

Abstract: A vehicle power module assembly including an array of stacked switch unit assemblies, a front cover, first and second side rails, and an end cover is provided. Each of the assemblies may include a power stage frame having a mid-cutout located at a substantially central side frame region such that a mid-cutout region is defined along each side of the array. The front cover may be disposed at a first end of the array. The first and second side rails may each extend from the front cover and each may be disposed within one of the mid-cutout regions such that an outer surface of each side rail is substantially flush with an outer surface of a respective power stage frame. The end cover may be arranged with the front cover to retain the assemblies therebetween. The assembly may further include a clamping plate and a spring element.

Abstract: A vehicle power module assembly including an array of stacked switch unit assemblies, a front cover, first and second side rails, and an end cover is provided. Each of the assemblies may include a power stage frame having a mid-cutout located at a substantially central side frame region such that a mid-cutout region is defined along each side of the array. The front cover may be disposed at a first end of the array. The first and second side rails may each extend from the front cover and each may be disposed within one of the mid-cutout regions such that an outer surface of each side rail is substantially flush with an outer surface of a respective power stage frame. The end cover may be arranged with the front cover to retain the assemblies therebetween. The assembly may further include a clamping plate and a spring element.