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: An electric machine for an electrified vehicle includes a stator core configured to receive a plurality of windings and an overmolded midsection formed about the stator core. The midsection also defines a first interlocking feature disposed near an end face of the stator core. The electric machine also includes an end cap defining at least a portion of a coolant channel and a second interlocking feature configured to engage the first interlocking feature and create a fluid seal to retain fluid within the coolant channel. The coolant channel is further arranged to encase end portions of the plurality of windings and direct circulating coolant across the end portions.

Abstract: A vehicle, electric machine, and method of manufacturing an electric machine include a stator having teeth extending from a yoke portion toward a rotor and defining slots between adjacent teeth with windings positioned within the slots, wherein the slots are coated with an electrically insulating material having an arcuate surface exiting the slots and extending at least partially over the teeth on at least one end face of the stator to form a winding guide for bending/positioning the windings. The winding guide may be formed by a molded epoxy that replaces insulating paper slot liners while providing a template for forming the hairpin bends of end windings.

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 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: A vehicle electric machine includes a housing, a stator supporting windings and disposed in the housing. The stator defines axial cooling channels having first ends located on a first end face of the stator and second ends located on a second end face of the stator. A plug is disposed in the second end of one of the axial channels and having an orifice.

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: An electric machine rotor that is configured to rotate about a first axis includes a plurality of plates and plurality of permanent magnets. The plurality of plates are stacked along the first axis. Each of the plates defines V-shaped pairs of cavities. Each V-shaped pair of cavities defines a pole arc angle. Each cavity has a permanent magnet pocket and a magnetic field guide chamber extending radially outward from the permanent magnet pocket relative to the first axis. Offset angles between the magnetic field guide chambers and the permanent magnet pockets vary within each plate. The plates are stacked such that the permanent magnet pockets between adjacent plates are axially aligned and such that the magnetic field guide chambers between adjacent plates are axially offset. Each permanent magnet extends through a set of permanent magnet pockets.

Abstract: An electric machine rotor includes a plurality of plates stacked along an axis of rotation. Each of the plates defines a plurality of cavities. Each cavity defines a pole arc angle, has at least one permanent magnet pocket, and has magnetic field guide chambers extending outward from the at least one permanent magnet pocket. Offset angles between the magnetic field guide chambers and the at least one permanent magnet pockets vary between at least two of the cavities of the plurality of cavities within each plate such that each plate defines at least two different pole arc angles. The plates are stacked such that the at least one permanent magnet pockets between adjacent plates are axially aligned and such that the magnetic field guide chambers between adjacent plates are axially offset.

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 includes a plurality of printed layers arranged to form a stator having an outer periphery and teeth extending radially inward from the outer periphery. Each of the printed layers includes discrete portions of metal and discrete portions of insulation. The discrete portions of insulation define a contiguous network of insulative boundaries separating discrete cells formed by the discrete portions of the metal. A volume of the discrete cells within the outer periphery is greater than a volume of the discrete cells within the teeth such that a reluctance of the teeth is greater than a reluctance of the outer periphery.

Abstract: A winding assembly for a stator has a plurality of bridges each including an arcuate center section extending circumferentially over an end surface of a core at a first axial level relative thereto, first and second necks contiguous with respective first and second ends of the center section and extending therefrom axially away from the end surface, and first and second blocks contiguous with the respective necks and connected to the respective terminals of a pair of conductors at a second axial level farther from the end surface than the first axial level.

Abstract: A vehicle electric machine assembly including a stator core and a terminal block is provided. The stator core includes one or more three-phase terminals connected to end windings. The terminal block includes a connector for each of the three-phase terminals. A portion of the end windings extending from the stator core, the three-phase terminals, and the terminal block are overmolded as a single unit such that a portion of each of the connectors is exposed for connection to an inverter. The terminal block may further include one or more threaded apertures, each sized to receive a threaded stud to facilitate an electrical connection between one of the one or more three-phase terminals and the inverter. Each of the one or more three-phase terminals may extend axially along an axis substantially parallel to a central axis of a rotor disposed within a cavity defined by the stator core.

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 have iron particles embedded therein such the portions have magnetic permeability greater than other portions of the midsection lacking the iron particles.

Abstract: A stator for an electric machine is fabricated by assembling a core and first and second winding assemblies. The first winding assembly (FWA) is fabricated by a 3D printing process and includes a plurality of U-shaped conductors (hairpins) having respective end-turns arranged in mutually axially-nested relationship to each other to form a ring, and further having two uprights disposed in one of the slots of the core. End-turns connect respective pairs of the uprights and are disposed adjacent to an end surface of the core, distal ends of the uprights projecting axially beyond an opposite end surface of the core. The second winding assembly (SWA) includes a plurality of bridges forming a second ring Opposite ends of each bridge define terminals that mate with ends of the uprights. The SWA further includes an electrically non-conductive casing in which at least one of the bridges is embedded.

Abstract: An electric machine rotor includes a plurality of plates stacked along an axis of rotation. Each of the plates defines a plurality of cavities. Each cavity defines a pole arc angle, has at least one permanent magnet pocket, and has magnetic field guide chambers extending outward from the at least one permanent magnet pocket. Offset angles between the magnetic field guide chambers and the at least one permanent magnet pockets vary between at least two of the cavities of the plurality of cavities within each plate such that each plate defines at least two different pole arc angles. The plates are stacked such that the at least one permanent magnet pockets between adjacent plates are axially aligned and such that the magnetic field guide chambers between adjacent plates are axially offset.

Abstract: A method of forming an annealed magnet includes positioning a magnetizing array ring concentrically with a ring of bulk magnetic material to form an assembly, the magnetizing array ring having a magnetic field defining directions for orienting grains of the ring of bulk magnetic material, placing the assembly in a furnace, and operating the furnace to anneal the ring of bulk magnetic material and grow the grains in the directions. A magnetic array assembly includes a furnace; and an assembly including (i) a ring of bulk magnetic material having grains and (ii) a magnetizing array ring concentric with the ring of bulk magnetic material, and having a magnetic field defining directions for orienting the grains during growth thereof in a presence of heat from the furnace.

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 have iron particles embedded therein such the portions have magnetic permeability greater than other portions of the midsection lacking the iron particles.

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.