Abstract: An electrical machine includes a stator assembly having an annular core and a conductive winding. The annular core includes a central bore. The conductive winding includes one or more stator winding bars disposed circumferentially around the central bore. The one or more stator winding bars include a core conductor and an insulation layer surrounding the core conductor. An end segment of the one or more stator winding bars at a connection interface includes a stress control structure surrounding the insulation layer. The stress control structure includes a printed scaffold and a dielectric backfill material. The dielectric backfill material fills pores of the printed scaffold. The porous scaffold is composed of a stress control material that is different from the dielectric backfill material.

Abstract: An insulative assembly includes an insulative mica-based carrier film and first and second resistive grading layers joined to opposite sides of the mica-based carrier film. The first resistive material layer is configured to engage one or more conductors and insulate the one or more conductors from at least one other conductor. A method for creating an insulative assembly for one or more conductors includes obtaining an insulative mica-based carrier film, depositing a first resistive grading layer on a first side of the mica-based carrier film, and depositing a second resistive grading layer on an opposite, second first side of the mica-based carrier film.

Abstract: An electrical machine includes a stator assembly having an annular core and a conductive winding. The annular core includes a central bore. The conductive winding includes one or more stator winding bars disposed circumferentially around the central bore. The one or more stator winding bars include a core conductor and an insulation layer surrounding the core conductor. An end segment of the one or more stator winding bars at a connection interface includes a stress control structure surrounding the insulation layer. The stress control structure includes a printed scaffold and a dielectric backfill material. The dielectric backfill material fills pores of the printed scaffold. The porous scaffold is composed of a stress control material that is different from the dielectric backfill material.