Abstract: A permanent magnet electric machine includes a housing, a stator mounted within the housing, and a rotor assembly rotatably mounted within the housing relative to the stator. The rotor assembly includes a rotor body having a plurality of rotor laminations. A plurality of permanent magnets having axial end portions is mounted to the rotor body. An amount of thermal interface material (TIM) is arranged between the axial end portions of adjacent ones of the plurality of permanent magnets.

Abstract: An electric machine includes a stator core having a plurality of circumferentially-oriented slot positions, each slot position having a plurality of radially-oriented slots, each slot extending longitudinally through the core. The stator core has a plurality of conductor segments each extending through at least one of the slots. When a slot position is populated with at least two conductor segments, at least two exterior conductor portions exiting the slot position are angled radially apart from one another by more than one degree. A method of cooling an electric machine includes providing coolant access to embedded conductor end turn portions of a stator having circumferentially spaced slot positions by radially spreading exterior conductor portions exiting populated ones of the slot positions.

Abstract: A stator core includes a plurality of slot segments, a plurality of stator winding conductors arranged in select ones of the plurality of slot segments, and a ceramic covering provided on one or more of the plurality of stator winding conductors. The ceramic covering includes an adhesive bonded to the one of the plurality of stator winding conductors to provide insulation for the one or more stator winding conductors.

Abstract: A method of forming a rotor includes placing a plurality of laminations into a stack having a plurality of longitudinally extending magnet slots, placing a plurality of permanent magnets into ones of the magnet slots, and injecting a low viscosity epoxy resin into the lamination stack, thereby substantially filling the magnet slots with a portion of the epoxy resin having a thermal conductivity greater than 0.3 Watts/(meter*degree Kelvin) and substantially filling axial spaces between adjacent ones of the laminations with a portion of the epoxy resin having a thermal conductivity less than that of the epoxy resin in the magnet spaces.

Abstract: A permanent magnet electric machine including a housing, a stator mounted within the housing, and a rotor assembly rotatably mounted within the housing relative to the stator. The rotor assembly includes a plurality of laminations. Each of the plurality of laminations includes a plurality of slots and one or more permanent magnets mounted within respective ones of the plurality of slots. Each of the plurality of permanent magnets includes a sacrificial coating formed from a thermal interface material (TIM).

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: 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: An interlock system and method are provided for protecting high voltage electrical couplings. The interlock system may control access to the electrical couplings based on the voltage of the electrical couplings. The interlock system may also selectively energize and de-energize the electrical couplings based on the position of a lid.

Abstract: A method of manufacturing an electric machine that includes providing a core defining a slot, coating a magnet body prior to installation of the magnet body into the slot and installing the magnet body into the slot wherein the coating on the magnet body has a thermal conductivity of at least about 0.3 W·m?1·K?1, advantageously of at least about 0.5 W·m?1·K?1, and even more advantageously of at least about 2 or 3 W·m?1·K?1 and wherein the coating is in a partially cured condition when the magnet body is inserted into the slot. The coating may form a substantially voidless material bridge between the magnet body and the core over at least a portion of the magnet body and thereby thermally couple the magnet body with the core. An electric machine manufactured in accordance with the method is also disclosed.

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: A terminal block holder is provided for securing a terminal block assembly having at least three conductive bus bars enclosed within corresponding individual insulating columns passing through a housing of an electric machine, the terminal block holder including a plate defining at least three openings therein, and including first and second dividers extending from the plate and respectively separating different adjacent ones of the openings, where the plate is adapted to abut the terminal block assembly in a first direction, where the plate is adapted to abut the housing in a second direction, where the dividers are adapted to abut the terminal block assembly in a third direction, and where the first, second and third directions are substantially perpendicular to one another.

Abstract: A stator assembly includes a first conductor having a first leg portion, and second leg portion. Each of the first and second leg portions includes corresponding first and second free end portions. The first free end portion includes first and second surface portions and the second free end portion includes first and second surface segments. A second conductor includes a first leg section, and a second leg section including corresponding first and second free end sections. The first free end section includes first and second surface zones and the second free end section including first and second surface sectors. The second free end portion and the first free end section are twisted creating a cross-over region causing the first surface portion to abut the second surface zone. The second free end portion is joined to the first free end section through a bond that exists at the cross-over region.

Abstract: An electric machine and vehicular subsystem, apparatus includes a connection disposed within a housing and connecting a high voltage line with the electric machine. A controller controls the coupling of a power source to the high voltage line. A reed switch is positioned within the housing proximate the high voltage line connection. A member is removably mounted on the housing and structured so that removal of the member is necessary to gain access to the high voltage line connection, the member having a magnet. At least one low voltage communication line extends from the reed switch to the controller. Removal of the member from the housing opens the reed switch. Mounting of the member to the housing closes the reed switch. The controller terminates the providing of electric power to the high voltage line when the member is removed from the housing.

Abstract: An electric power source supplies electrical power to an electric machine of a vehicle via a plurality of high voltage lines. A plurality of connections are disposed within a housing for connecting the high voltage lines. A cover member encloses a hidden magnet and is removably secured to the housing so that removal is necessary to obtain access to the high voltage lines. A reed switch is mounted proximate the cover member, when secured, within a magnetic field of the magnet, whereby the reed switch is closed when the cover member is secured and is open when the cover member is removed. A controller is controllably coupled to the power source via a control connector and circuit of the electric machine. Such circuit extends from the reed switch to the controller, where the controller causes the electric power source to stop supplying electrical power when the cover member is removed.

Abstract: A method of joining a plurality of electrical conductors in an electric machine comprises the steps of providing a core with a plurality of circumferentially spaced openings, and positioning a plurality of conductors within the openings of the core in a plurality of concentric layers. Each conductor includes an end that extends from the core. The ends of the conductors have a first shape. The method also includes the step of shaping the ends of the conductors with a set of forming dies to form a second shape. Additionally, the method includes the step of joining a pair of adjacent ends with a joining tool to form a joint with a third shape after shaping the ends to form the second shape. The method further includes the step of removing the set of forming dies and the joining tool from the joint after the joining step.

Abstract: An electric machine having a rotor and a stator. The stator includes an electrically conductive wire forming a stator winding. The stator winding forms a first plurality of end turns projecting axially beyond an axial end of the stator core. Each of the wire segments forming the first plurality of end turns has a discrete electrically insulative outer layer. A heat transmissive material having a thermal conductivity of at least about 50 W•m?1•K?1 encapsulates the first plurality of end turns. A ceramic material may be used to provide the electrically insulative outer layer of the winding and a metallic material may be used to form the heat transmissive material encapsulating the end turns. A method of manufacture is also disclosed.

Abstract: A slot liner is configured for insertion into a slot of a core of an electric machine having a winding arrangement comprised of a plurality of conductors. The slot liner comprises a first insulation layer forming a cavity configured to receive at least one of the plurality of conductors of the winding arrangement. The slot liner also comprises a second insulation layer coupled to the first insulation layer. In addition, the slot liner includes a length of conductive material positioned between the first insulation layer and the second insulation layer. The length of conductive material has a resistance that varies with temperature. A first lead extends from a first end of the length of conductive material and a second lead extends from the second end of the length of conductive material.

Abstract: A composite sleeve for a conductor including a conductor having an outer surface, a first sleeve positioned about the outer surface of the conductor, and a second sleeve positioned about the first sleeve. One of the first and second sleeves is formed from a compressed amide synthetic fiber. The first and second sleeves cooperate to provide protection for the conductor from external elements.

Abstract: A stator includes a stator core having a plurality of slot segments, a plurality of stator winding conductors arranged in select ones of the plurality of slot segments, a jumper conductor interconnecting select ones of the plurality of stator winding conductors to form one or more stator windings, a common conductor connected to at least one of the stator winding conductors, a phase conductor connected to corresponding ones of the one or more stator windings, and a composite sleeve provided on at least one of the jumper conductor, the common conductor, and the phase conductor. The composite sleeve includes a first sleeve, and a second sleeve positioned about the first sleeve. One of the first and second sleeves is formed from a compressed amide synthetic fiber. The first and second sleeves cooperate to provide protection for the conductor from external elements.

Abstract: A method of insulating a conductor wire comprises the steps of providing an electrically conductive core having a longitudinal axis and applying an electrical insulation material to an outer surface of the core. The method further comprises the steps of elevating the temperature of the electrical insulation material and applying external pressure to the electrical insulation material to facilitate adhesion with the core.