Abstract: A method of processing an anisotropic permanent magnet includes forming anisotropic flakes from a hulk magnet alloy, each of the anisotropic flakes having an easy magnetization direction with respect to a surface of the flake and combining the anisotropic flakes with a binder to form a mixture. The method further includes extruding or rolling the mixture without applying a magnetic field such that the easy magnetization directions of the anisotropic flakes align to form one or more layers having a magnetization direction aligned with the easy magnetization directions of the anisotropic flakes, and producing the anisotropic permanent magnet from the layers having the magnetization direction such that the anisotropic permanent magnet has a magnetization with a specific orientation.

Abstract: Permanent magnets and method of making the same are provided. The magnets include a magnetic layer having an insulation layer disposed thereon. The insulation layer is formed via additive manufacturing techniques such as laser melting such that that it has discrete phases including a magnetic phase and an insulating phase.

Abstract: A vehicle electric machine includes a stator core having an inner diameter defining a plurality of slots, an outer diameter, and a plurality of mounting ears disposed radially outboard of the outer diameter. At least one of the mounting ears defines a cooling channel extending in an axial direction of the stator core. A radial distance between a center of the stator core and the cooling channel is greater than a radial distance between the center and the outer diameter. The machine further includes windings having portions disposed in the slots and end windings adjacent to an end face of the stator core.

Abstract: Permanent magnets and method of making the same are provided. The magnets include a magnetic layer having an insulation layer disposed thereon. The insulation layer is formed via additive manufacturing techniques such as laser melting such that that it has discrete phases including a magnetic phase and an insulating phase.

Abstract: A stator includes a plurality of same laminations each defining a piloting tab on a perimeter thereof, and stacked to form a stator body and such that the piloting tabs define at least two axially extending serrated edge portions spaced apart from one another around a perimeter of the stator body or at least two sets of axially aligned housing contact pads spaced apart from one another around the perimeter.

Abstract: A vehicle electric machine includes a housing and a stator having windings and a stator core. The core defines a plurality of axially extending cooling channels each having an entrance port at one end of the stator and an exit port at the other end of the stator. An end cover is connected to a first end of the housing defining a recessed cavity configured to receive the windings and defines an arcuate inlet manifold channel that extends in a circumferential direction of the stator to partially circumscribe the first cavity and that is in fluid communication with first ones of the axial cooling channels.

Abstract: An electric machine includes a housing, a stator, an oil film, and at least one first seal. The housing has an internal surface defining an internal cavity. The stator has an outer peripheral surface and is disposed within the internal cavity such that a clearance gap is defined between an outer peripheral surface and the internal surface. The oil film is disposed within the clearance gap and is in contact with the internal surface and the outer peripheral surface. The at least one first seal is disposed along a first end of the stator and is configured to retain the oil film within the clearance gap along the first end of the stator.

Abstract: An electric machine including a stator core having an outer circumferential surface and an axial row of raised projections that extend radially outboard from the outer surface. The raised projections are axially spaced from each other to define circumferential channels therebetween. A housing defines a cavity that receives the stator core. The housing has an inner circumferential surface in contact with the raised projections and radially spaced from the outer surface of the core to define a void space in fluid communication with the channels. The void space and the channels cooperate to form a fluid circuit that overlays the outer circumferential surface such that the fluid is in direct contact with the stator core.

Abstract: This disclosure relates to thermal management for an electric machine, such as an electric motor, of an electrified vehicle. An example assembly includes a stator having a core and a jacket at least partially surrounding the core. The jacket radially encloses a slot and is configured to permit fluid to flow within the slot from a first face of the stator to a second face of the stator. The assembly further includes a first end cover covering the first face of the stator. The first end cover has an inlet port and is configured to direct fluid from the inlet into the slot. Further, the assembly includes a second end cover covering the second face of the stator and configured to direct fluid that exits the slot.

Abstract: An electrical current sensing arrangement includes a busbar, a dielectric material containing therein a magnetic field sensor, and a ferromagnetic over-mold encapsulating a portion of the busbar and the dielectric material. The dielectric material is disposed against the busbar such that the magnetic field sensor is spaced away from the busbar and the ferromagnetic over-mold is not between the busbar and the magnetic field sensor.

Abstract: A stator includes a core and an over-molded midsection arranged to define a plurality of slots, and a plurality of conductors wound within the slots. Portions of the midsection immediately adjacent to the slots define a plurality of protrusions disposed on opposite long faces of at least some of the slots. The protrusions extend into the at least some of the slots and between some of the conductors to establish a gap between the some of the conductors and to direct coolant between the some of the conductors.

Abstract: Magnetic cores including a bonding material having magnetic filler therein is disclosed, as well as devices including the same. The magnetic cores may have superior magnetic properties or adopt the benefits of both soft magnetic composite cores and laminate cores. The magnetic cores disclosed herein exhibit greater relative magnetic permeability in the normalized direction as well as greater saturation flux density.

Abstract: A rotor for an electric machine includes pairs of magnets with a bridge region therebetween. Lamination that comprise the rotor may define openings in the bridge region between the magnets of each of the pairs. A clip may be installed in the openings and a bonding material may fill the remainder of the bridge region.

Abstract: A rotor for an electric machine includes a core comprised of stacked laminations that define pockets between a hub portion and a pole portion. Each of the pockets are configured to receive magnetic material and define center cavities between regions of magnetic material to eliminate a flux leakage path between the magnetic materials. A cured mixture including an epoxy and a magnetic powder is disposed within the center cavities. The magnetic material may include sintered magnets and a cured mixture.

Abstract: A stator includes a core and a molded midsection arranged to define a plurality of slots. The stator also includes a plurality of conductors wound within the slots. Portions of the midsection immediately adjacent to the slots include magnetic insulator embedded therein. The magnetic insulator is electrically insulating and has ferrimagnetic ordering. The stator further includes a plurality of non-magnetic wedges disposed between the conductors and an inner diameter surface of the stator.

Abstract: A core for an electrical apparatus includes a plurality of electrical steel sheets having a ferromagnetic or ferrimagnetic coating applied to both sides of the electrical steel sheets. The electrical steel sheets are arranged in a stack to form a laminated stack. The ferromagnetic or ferrimagnetic coating is applied to both sides of the electrical steel sheets. The coating may comprise MnZn ferrites, NiZn ferrites, MgMnZn ferrites, CoNiZn ferrites, Co ferrites, Ni ferrites, Yttrium iron garnets (Y3Fe5O12) or other ferromagnetic or ferrimagnetic coating materials.

Abstract: A stator includes a plurality of same laminations each defining a piloting tab on a perimeter thereof, and stacked to form a stator body and such that the piloting tabs define at least two axially extending serrated edge portions spaced apart from one another around a perimeter of the stator body or at least two sets of axially aligned housing contact pads spaced apart from one another around the perimeter.

Abstract: An electric machine for an electrified vehicle includes a stator core configured to receive a plurality of windings. The stator core including a plurality of interchangeable stacked laminations arranged in sub-stacks. The sub-stacks having an outer diameter surface divided into circumferential quadrants, each quadrant having a cutout extending inwardly at a predetermined depth and radial position to define a serpentine cooling path on the outer surface of at least a portion of the sub-stacks. The sub-stacks are circumferentially rotated relative to each other such that two quadrants have a first cutout orientation, and the two other quadrants have a second cutout orientation, the first cutout orientation is different than the second cutout orientation and when rotated in sequence each cutout aligns to form the continuous serpentine cooling path in a quadrant of the stator core.

Abstract: An electric machine stator includes a soft magnetic yoke having a cylindrical yoke body extending along a central axis, with an outer surface and an inner periphery defining a central opening about the central axis, and a plurality of soft magnetic stator teeth. Each stator tooth defines a first set of air pockets, and a second set of air pockets. An electric machine rotor and permanent magnet material with air pockets are also provided.

Abstract: An electric machine includes a stator formed from a plurality of stacked laminations and defining a center bore and a rotor disposed within the center bore. The rotor is configured to output a rotational torque in response to an input current delivered to the stator. At least one of the stacked laminations of the stator includes a pattern of perforations disposed at a yoke portion of the stator to attenuate structure-bore transmission of vibration during operation of the electric machine.