Abstract: An electric motor assembly includes a stator defining a first interior space, a rotor positioned within the first interior space and configured for rotation relative to the stator, the rotor defining a second interior space, and a planetary gear assembly associated with the rotor and at least partially positioned within the second interior space.

Abstract: A stator assembly includes a coil isolator having a first flange, a phase separator, and a living hinge connecting the first flange and the phase separator, the coil isolator structured for enclosing a stator lamination stack and for winding a coil thereon in electrical isolation from the stack, the phase separator being radially closeable for enclosing a portion of the coil within the coil isolator. A method of forming a stator includes placing an isolator onto a lamination stack segment, winding a coil onto the isolator, folding a phase separator of the isolator to enclose a portion of the coil, and placing a plurality of bus bars onto the phase separator in physical partition from one another. A method of insulating a phase bus from a stator coil includes forming a coil insulator having a bobbin, a phase separator, and a living hinge coupling the bobbin to the phase separator.

Abstract: A stator assembly of an electric machine includes a segmented lamination stack formed of an interconnected series of lamination segment stacks, and a plurality of coil isolators each having a conductor wound thereon, each having a radially outward interlock at each circumferential end thereof, and each having a radially inward interlock at each circumferential end thereof, the coil isolators being serially connected by the interlocks to form a cavity closed down the axial length of the stator assembly, the coil isolators electrically insulating the lamination segments from the conductors.

Abstract: A buss bar assembly for a multiphase electric machine. The buss bar assembly includes a substantially annular dielectric housing having a central axis. A plurality of dielectric mounting members is located within the housing. A buss bar plate assembly is disposed in the housing, and in engagement with the mounting members. The buss bar plate assembly includes a substantially planar dielectric substrate that has opposing, substantially planar axial sides, and substantially surrounds the central axis. The buss bar plate assembly also includes a plurality of electrically conductive phase bars applied to at least one of the opposing substrate sides. Each phase bar is for electrical connection to a different one of multiple electrical phases and substantially surrounds the central axis, with the phase bars being electrically isolated from each other within the housing.

Abstract: A buss bar assembly for a multiphase electrical machine, including a substantially annular dielectric housing having a central axis, a plurality of dielectric phase bar mounting members located within the housing, and a plurality of electrically conductive phase bars. The phase bars are disposed in the housing and substantially surround the central axis. Each phase bar has opposing, substantially planar axial sides and is in engagement with at least one phase bar mounting member. An axial side of each phase bar is in superposition with an axial side of another phase bar whereby the plurality of phase bars are axially stacked along the central axis. The phase bars have mutually spaced positions relative to each other in directions along the central axis, these positions defined by the phase bar mounting members whereby the phase bars are electrically isolated from each other within the housing.

Abstract: An electric machine having a segmented core wherein the core includes a plurality of core segments. The segments are secured together with a belt member that substantially encircles the core segments but does not extend the full axial length of the segments. In some embodiments, the individual segments include a recess on their outer radial surface in which the belt member is positioned. A method of assembling an electric machine having a segmented core is also disclosed. Coils are wound about the poles of a plurality of segments. After forming the coils on the segments, the segments are joined together with a belt member wherein the belt member does not extend the full axial length of the core segments and is positioned between the two axial ends of the core assembly.

Abstract: A stator includes a body portion having an outer portion and an inner portion that defines an interior region, a plurality of stator teeth members extending from the inner portion into the interior region, and at least one continuous conductor wound around select ones of the plurality of stator teeth members to form at least one pole. Each of the plurality of stator teeth members including a number of wraps of the at least one continuous conductor. The at least one continuous conductor including a number of twists that is fewer than the number of wraps.

Abstract: An assembly of an electric machine includes a plurality of conductor segments each having a turn portion, and a plurality of clips each having a channel member and a bend member, the channel members being attached to respective ones of the conductor segments and thereby holding the respective bend members against the respective turn portions. The attached clips electrically insulate and space adjacent ones of the conductor segments. The bend members prevent adjacent ones of the conductor segments from contacting one another.

Abstract: Embodiments of the invention provide an electric machine module. The module can include a housing that can define a machine cavity. The housing can include a sleeve member that can include a first axial sleeve member comprising a first flange, a second flange, and first recess at least partially defined between the first flange and the second flange. The sleeve member can also include a second axial sleeve member comprising a third flange, a fourth flange, and a second recess at least partially defined between the first flange and the second flange. The first axial sleeve member can be coupled to the second axial sleeve member to form the sleeve member and so that the first recess and the second recess form a coolant jacket. An electric machine can be positioned within the machine cavity so that it is substantially circumscribed by a portion of the coolant jacket.

Abstract: An electric machine includes a core with a plurality of slots. A plurality of conductors are positioned in each of the plurality slots, with each slot including an equal number of conductors. At least one slot liner is also positioned in each of the plurality of slots. Each slot liner provides at least one slot liner channel in the associated slot, and each of the plurality of conductors extend through one of the slot liner channels. Differing numbers of slot liner channels are provided in the plurality of slots. Accordingly, all slots have the same number of conductors positioned therein, but all slots do not have the same number of slot liner channels.

Abstract: An electric machine includes a rotor lamination assembly having a lamination member formed from a material having a first yield strength. The lamination member includes a first bridge portion having a first width, and a first bridge zone having a first thickness. The rotor lamination assembly also includes at least one lamination section having a second bridge zone having a second thickness. The second thickness is greater than the first thickness. The rotor lamination assembly further includes at least one lamination element formed from a second material having a second yield strength that is higher than the first yield strength, and at least one lamination component. The at least one lamination component includes a second bridge portion having a second width. The second width is greater than the first width.

Abstract: Some embodiments of the invention provide an electric machine module including a housing that defines a machine cavity. A coolant jacket can be at least partially defined by the housing. In some embodiments, a plurality of coolant apertures can be disposed through portions of the housing to fluidly connect the coolant jacket and the machine cavity. One or more solenoid assemblies can be at least partially supported by the housing and positioned substantially adjacent to at least some of the coolant apertures. The solenoid assemblies can be configured to regulate passage of a coolant into the machine cavity from the coolant jacket.

Abstract: A synchronous electric machine includes a rotor having a substantially cylindrical core with axially extending slots, a plurality of permanent magnets configured as sets defining alternating poles in a circumferential direction, the permanent magnets being located in respective ones of the slots, and a thermally conductive material contiguous with the permanent magnets and the core for transferring heat of the permanent magnets, the material having a thermal conductivity of greater than 0.3 watts per (meter * Kelvin).

Abstract: Embodiments of the invention provide an electric machine module comprising a module housing. In some embodiments, the module housing can include a sleeve member and at least one end cap. Also, an inner wall of the module housing can at least partially define a machine cavity. In some embodiments a coolant jacket can be positioned within a portion of the sleeve member. Further, in some embodiments, at least one partition can be positioned substantially within the coolant jacket. The partition can be dimensioned to at least partially seal a first region of the coolant jacket from a second region of the cooling jacket.

Abstract: A planetary gear assembly includes a ring gear configured for connection to a rotor of an electric motor when in a first position and configured for connection to a housing of the electric motor when in a second position, a sun gear configured for connection to the housing when the ring gear is in the first position and configured for connection to the rotor when the ring gear is in the second position, and a plurality of planet gears configured to mesh with the ring gear and the sun gear.

Abstract: An electric machine including a housing, a stator mounted within the housing, a rotor rotatably mounted within the housing relative to the stator, and a vibration sensor arranged within the housing. The vibration sensor includes a sensing member configured and disposed to detect vibrations of the electric machine.

Abstract: Embodiments of the invention provide an electric machine module including a stator assembly. The stator assembly includes a stator core comprising a plurality of slots. Conductors can be at least partially disposed within the slots. The conductors can include leg portions and can be positioned so that at least some of the slots include a first leg portion, a second leg portion, a third leg portion, and a fourth leg portion. The stator assembly can include first clearance apertures defined by between circumferentially adjacent first leg portions, second clearance apertures that can be defined between circumferentially adjacent second leg portions, third clearance apertures that can be defined between circumferentially adjacent third leg portions, and fourth clearance apertures that can be defined between circumferentially adjacent fourth leg portions. In some embodiments, the second and third clearance apertures can comprise a greater circumferential size relative to the first and fourth clearance apertures.

Abstract: A method of blocking electro-magnetic interference (EMI) in an electric machine having a housing including an interior portion, an opening leading to the interior portion, and an enclosure positioned about the opening, includes positioning an EMI blocking member in the enclosure across the opening. The EMI blocking member includes an insulating layer having a first surface and a second surface. An EMI shield member is positioned on one of the first and second surfaces. The EMI shield member includes a surface formed from an electrically conductive material that substantially covers the one of the first and second surfaces. The EMI shield member is grounded to the housing. The EMI shield member is configured and disposed to block EMI release from the housing via the enclosure.

Abstract: Embodiments of the invention provide an electric machine module including a module housing, which can at least partially define a machine cavity. In some embodiments, an electric machine can include a stator assembly and a rotor assembly and can be positioned in the machine cavity. In some embodiments, the module housing can include a coolant transport network, which can include at least one passage in fluid communication with at least one first annulus and at least one second annulus. In some embodiments, the first annulus can be substantially axially adjacent to an axial end of the stator assembly and the second annulus can be substantially axially adjacent to an axial end of the rotor assembly. In some embodiments, the annuli can include a plurality of annulus apertures.

Abstract: Embodiments of the invention provide an electric machine module including a housing. The housing can include a machine cavity. In some embodiments, an electric machine can be at least partially positioned within the machine cavity and can include a stator assembly. The stator assembly includes a stator core with slots. In some embodiments, conductors can be positioned in the slots. The conductors include a turn portion extending between leg portions. The leg portions include an angled portion and a connection portion. The conductors are disposed within the plurality of slots so that the angled and connection portions extend from the stator core at a first axial side. At least one insulation member can be disposed over at least some of the leg portions so that the connection portions are at least partially uncovered.