Abstract: An apparatus for providing a coolant to a stator and a rotor of an electric motor in a vehicle having a coolant pump is provided. The apparatus includes a base defining a plurality of first openings through at least one of which the coolant is flowable to the stator. The apparatus also includes at least one wall extending from the base to define a cavity configured to receive the coolant from the coolant pump. The apparatus further includes at least one first raised member within the cavity that extends from the base. The at least one first raised member defines at least one second opening substantially aligned with one of the first openings to form a first passageway through which the coolant is flowable to the rotor. The apparatus may be located above the electric motor such that the coolant is flowable by gravity to the stator and/or the rotor.

Abstract: A coil retainer for a rotor includes a flat body and a longitudinal spine. The flat body has a first thickness and the longitudinal spine has a second thickness greater than the first thickness. The coil retainer may also include a central rib, which has a third thickness. The central rib runs laterally relative to the flat body and the third thickness of the central rib is greater than the first thickness.

Abstract: A rotor defines an axial direction and a radial direction relative to an axis of rotation and includes an annular hub and a core disposed radially outward of the annular hub. The core defines a first axial side and a second axial side. First radial feed holes are formed in the annular hub, and are located between the first and second axial sides. Axial channels are formed between the core and the annular hub, and are in fluid communication with the first radial feed holes and span substantially between the first and second axial sides. The rotor also includes a first member and a second member, adjacent to the first and second axial sides, respectively. First and second apertures are formed in the first and second members, respectively. Each of the first and second apertures is in fluid communication with one of the axial channels.

Abstract: A support ring for a rotor having a core and a plurality of windings. The support ring includes an annular base, a plurality of fingers, and a plurality of loaded edges. The plurality of fingers extend radially outward from the annular base, and each generally corresponds to one of the windings. The plurality of loaded edges extend axially from the fingers and are disposed radially outward of the windings.

Abstract: An apparatus for providing a coolant to a stator and a rotor of an electric motor in a vehicle having a coolant pump is provided. The apparatus includes a base defining a plurality of first openings through at least one of which the coolant is flowable to the stator. The apparatus also includes at least one wall extending from the base to define a cavity configured to receive the coolant from the coolant pump. The apparatus further includes at least one first raised member within the cavity that extends from the base. The at least one first raised member defines at least one second opening substantially aligned with one of the first openings to form a first passageway through which the coolant is flowable to the rotor. The apparatus may be located above the electric motor such that the coolant is flowable by gravity to the stator and/or the rotor.

Abstract: A coil retainer for a rotor includes a flat body and a longitudinal spine. The flat body has a first thickness and the longitudinal spine has a second thickness greater than the first thickness. The coil retainer may also include a central rib, which has a third thickness. The central rib runs laterally relative to the flat body and the third thickness of the central rib is greater than the first thickness.

Abstract: A stator having a common varnish and weld insulation includes a stator lamination core and a motor winding wound around the stator lamination core. The motor winding includes a plurality of magnet wires configured such that they are substantially parallel to each other. Each magnet wire has two distal ends configured such that each distal end is welded to one distal end of an adjacent magnet wire, thereby forming a plurality of welded tips. The stator further includes a resin coating the welded tips and the stator. The resin serves as both a primary insulation for the welded tips, and as a varnish for the stator. This dual function of the resin may eliminate the need for separate insulation for the welded tips and varnish for the stator, and allow the resin to be applied to the welded tips and to the stator at substantially the same time.

Abstract: A rotor defines an axial direction and a radial direction relative to an axis of rotation and includes an annular hub and a core disposed radially outward of the annular hub. The core defines a first axial side and a second axial side. First radial feed holes are formed in the annular hub, and are located between the first and second axial sides. Axial channels are formed between the core and the annular hub, and are in fluid communication with the first radial feed holes and span substantially between the first and second axial sides. The rotor also includes a first member and a second member, adjacent to the first and second axial sides, respectively. First and second apertures are formed in the first and second members, respectively. Each of the first and second apertures is in fluid communication with one of the axial channels.

Abstract: A support ring for a rotor having a core and a plurality of windings. The support ring includes an annular base, a plurality of fingers, and a plurality of loaded edges. The plurality of fingers extend radially outward from the annular base, and each generally corresponds to one of the windings. The plurality of loaded edges extend axially from the fingers and are disposed radially outward of the windings.

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.