Abstract: A lamination system is contemplated. The system may have a modular design configured to fabricate a laminate from an incoming material. The system may be configured to produce the laminate with an outer layer comprising the incoming material such that the resulting layer has a width greater than a width of the incoming material prior to lamination.

Abstract: A lamination system is contemplated. The system may have a modular design configured to fabricate a laminate from an incoming material. The system may be configured to produce the laminate with an outer layer comprising the incoming material such that the resulting layer has a width greater than a width of the incoming material prior to lamination.

Abstract: A method of forming edge materials on an electrochemical cell component having a metallic foil substrate including a conductive coating on top and bottom surfaces and first and second edge portions extending laterally outward beyond the conductive coating, includes pulling the metallic foil substrate from a roll, feeding the metallic foil substrate through a profile machine and forming notches within the first and second edge portions that extend inwardly from outermost edges of the first and second edge portions a distance less than a distance between the outermost edges and the conductive coating, and define a plurality of electrode tabs, feeding the strip of metallic foil substrate sequentially through a plurality of 3-dimensional printing machines and printing edge materials onto the electrode tabs and the first and second edge portions between the plurality of electrode tabs, and rolling the strip of metallic foil substrate onto a roll.

Abstract: A method of forming edge materials on an electrochemical cell component having a metallic foil substrate including a conductive coating on top and bottom surfaces and first and second edge portions extending laterally outward beyond the conductive coating, includes pulling the metallic foil substrate from a roll, feeding the metallic foil substrate through a profile machine and forming notches within the first and second edge portions that extend inwardly from outermost edges of the first and second edge portions a distance less than a distance between the outermost edges and the conductive coating, and define a plurality of electrode tabs, feeding the strip of metallic foil substrate sequentially through a plurality of 3-dimensional printing machines and printing edge materials onto the electrode tabs and the first and second edge portions between the plurality of electrode tabs, and rolling the strip of metallic foil substrate onto a roll.

Abstract: An insulation assembly is provided that includes a generally annularly-shaped main body and at least two spaced-apart fingers extending radially inwards from the main body. The spaced-apart fingers define a gap between the fingers. A slot liner may be inserted within the gap. The main body may include a plurality of circumferentially distributed segments. Each one of the plurality of segments may be operatively connected to another of the plurality of segments to form the continuous main body. The slot liner may be formed as a single extruded piece defining a plurality of cavities. A plurality of conductors (extendable from the stator assembly) may be axially inserted within a respective one of the plurality of cavities. The insulation assembly electrically isolates the conductors in the electric motor from the stator stack and from other conductors.

Abstract: A stator for an electric motor includes first and second rows of conductors arranged concentrically around an axis inside a steel core. Each conductor includes a linking end. The stator also includes a first dielectric shim ring arranged between the two rows of conductors. Each conductor of the first row is bent in either a clockwise or a counter-clockwise direction relative to the axis and each conductor of the second row is bent in the opposite direction. The linking end of each conductor of the first row is attached to the linking end of an adjacent conductor of the second row after the conductors are bent. The first shim ring separates the first and second rows of conductors when the conductors are being bent, and is also at least partially disposed between the first and second rows of conductors when the linking ends are being attached.

Abstract: A method of applying varnish to a stator includes orienting a center axis of the stator substantially parallel to gravity, and orienting a crown end of stator windings upward and a weld end of the windings downward, relative to gravity. The crown end and the weld end of the stator are disposed on opposing sides of the core. The weld end is placed above a dip tank and varnish applied to the crown end of the windings with at least one nozzle. The nozzle is controlled along a first direction and a second direction, which are perpendicular to the center axis. The varnish substantially coats the crown end of the windings, runs through the slots, and drips from the weld end of the windings into the dip tank. The dip tank is raised to submerse the weld end of the windings but not the core.

Abstract: A stator for an electric motor includes first and second rows of conductors arranged concentrically around an axis inside a steel core. Each conductor includes a linking end. The stator also includes a first dielectric shim ring arranged between the two rows of conductors. Each conductor of the first row is bent in either a clockwise or a counter-clockwise direction relative to the axis and each conductor of the second row is bent in the opposite direction. The linking end of each conductor of the first row is attached to the linking end of an adjacent conductor of the second row after the conductors are bent. The first shim ring separates the first and second rows of conductors when the conductors are being bent, and is also at least partially disposed between the first and second rows of conductors when the linking ends are being attached.

Abstract: An insulation assembly is provided that includes a generally annularly-shaped main body and at least two spaced-apart fingers extending radially inwards from the main body. The spaced-apart fingers define a gap between the fingers. A slot liner may be inserted within the gap. The main body may include a plurality of circumferentially distributed segments. Each one of the plurality of segments may be operatively connected to another of the plurality of segments to form the continuous main body. The slot liner may be formed as a single extruded piece defining a plurality of cavities. A plurality of conductors (extendable from the stator assembly) may be axially inserted within a respective one of the plurality of cavities. The insulation assembly electrically isolates the conductors in the electric motor from the stator stack and from other conductors.