Abstract: A motor stator includes a plurality of stacked annular stator laminates defining a stator core having an inner circumference, an outer circumference, a plurality of stator teeth on the inner circumference, and a plurality of ears extending outward from the outer circumference with a respective bolt hole defined in each ear. A first set of the stator laminates includes a plurality of coolant openings therethrough, wherein the coolant openings of adjacent stator laminates communicate with one another in order to define cooling channels inside the stator core. A second set of the stator laminates each include one or more generally radially extending first openings therethrough, wherein the first openings of adjacent stator laminates communicate with one another to define one or more first radial channel segments inside the stator core for providing radial coolant flow between one or more bolt holes and one or more cooling channels.

Abstract: A distributed connection ring assembly can be used in a stator assembly and can integrate a neutral connector and jumping winding connections in an overmolded assembly for insulation. The stator assembly including a stator core defining a plurality of slots spaced apart from each other, a plurality of bar conductors disposed in each of the slots, and a distributed connection ring assembly secured to the jumping winding connections. The distributed connection ring assembly includes an overmolded neutral connector. The distributed connection ring assembly also includes a plurality of overmolded couplers circumferentially spaced apart from one another. The overmolded couplers are coupled to the overmolded neutral connector. Each of the plurality of overmolded couplers includes a support body and a plurality of stator conductors partially disposed inside the support body. The stator conductors are electrically connected to the jumping winding connections.

Abstract: A connection support assembly for a stator assembly can be used to secure electrical jumper wires of an electric machine. The connection support assembly includes a support body and a catch protruding from the support body. The catch defines an opening. The connection support assembly further includes a clip coupled to the support body. The clip includes a clip body and a pin protruding from the clip body. The pin extends through the opening of the catch in order to couple the clip to the support body and clamp at least some electrical jumper wires between the support body and the clip.

Abstract: A distributed connection ring assembly can be used in a stator assembly and can integrate a neutral connector and jumping winding connections in an overmolded assembly for insulation. The stator assembly including a stator core defining a plurality of slots spaced apart from each other, a plurality of bar conductors disposed in each of the slots, and a distributed connection ring assembly secured to the jumping winding connections. The distributed connection ring assembly includes an overmolded neutral connector. The distributed connection ring assembly also includes a plurality of overmolded couplers circumferentially spaced apart from one another. The overmolded couplers are coupled to the overmolded neutral connector. Each of the plurality of overmolded couplers includes a support body and a plurality of stator conductors partially disposed inside the support body. The stator conductors are electrically connected to the jumping winding connections.

Abstract: A connection support assembly for a stator assembly can be used to secure electrical jumper wires of an electric machine. The connection support assembly includes a support body and a catch protruding from the support body. The catch defines an opening. The connection support assembly further includes a clip coupled to the support body. The clip includes a clip body and a pin protruding from the clip body. The pin extends through the opening of the catch in order to couple the clip to the support body and clamp at least some electrical jumper wires between the support body and the clip.

Abstract: An electrical connector assembly for attachment to a case includes a plurality of terminals, a carrier, and a single body seal. The terminals extend into a connector hole defined by the case and the carrier mates the terminals to the case. The carrier has a unibody formed as one-piece, with a sealing groove defined in the unibody. A plurality of terminal holes correspond to the terminals and extend through the unibody. The single body seal is compressed between the unibody of the carrier and a mating surface defined by the case.

Abstract: A rotor assembly for an electric machine includes a plurality of lamination sheets. Each of the lamination sheets defines an aperture. The lamination sheets are disposed adjacent each other to define a laminated stack. The apertures are aligned with each other to define a slot extending parallel with a central axis of the laminated stack. A magnet is disposed within the slot. The lamination sheets include a group of recess lamination sheets and a tab lamination sheet. The tab lamination sheet includes a tab that extends into the slot, and into abutting engagement with the magnet to bias the magnet against a wall of the slot. The apertures of the group of recess lamination sheets include a groove portion that defines a groove. The tab of the tab lamination sheet is at least partially disposed within the groove defined by the recess lamination sheets.

Abstract: A bar wound stator includes a stator core defining a plurality of slots. Bar-type conductors are disposed within each slot. Each slot includes a slot liner and an insulator cap. Each slot liner includes an end portion disposed against an inner wall surface, and side portions disposed against a first wall surface and a second wall surface respectively. Each insulator cap includes a base portion disposed against an outer wall surface, and side portions disposed against the first wall surface and the second wall surface respectively. The side portions of the insulator cap in each slot overlap the side portions of the slot liner in each slot along the first wall surface and the second wall surface respectively. Each slot includes a recessed feature in each of the first wall surface and the second wall surface to accommodate the overlapping side portions of the insulator cap and the slot liner.

Abstract: A rotor assembly for an electric machine includes a plurality of lamination sheets. Each of the lamination sheets defines an aperture. The lamination sheets are disposed adjacent each other to define a laminated stack. The apertures are aligned with each other to define a slot extending parallel with a central axis of the laminated stack. A magnet is disposed within the slot. The lamination sheets include a group of recess lamination sheets and a tab lamination sheet. The tab lamination sheet includes a tab that extends into the slot, and into abutting engagement with the magnet to bias the magnet against a wall of the slot. The apertures of the group of recess lamination sheets include a groove portion that defines a groove. The tab of the tab lamination sheet is at least partially disposed within the groove defined by the recess lamination sheets.

Abstract: A bar wound stator includes a stator core defining a plurality of slots. Bar-type conductors are disposed within each slot. Each slot includes a slot liner and an insulator cap. Each slot liner includes an end portion disposed against an inner wall surface, and side portions disposed against a first wall surface and a second wall surface respectively. Each insulator cap includes a base portion disposed against an outer wall surface, and side portions disposed against the first wall surface and the second wall surface respectively. The side portions of the insulator cap in each slot overlap the side portions of the slot liner in each slot along the first wall surface and the second wall surface respectively. Each slot includes a recessed feature in each of the first wall surface and the second wall surface to accommodate the overlapping side portions of the insulator cap and the slot liner.