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 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: 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 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 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 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: 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: 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 electric machine includes a stator with a core having an end face and a plurality of conductors forming windings that extend adjacent to the end face defining end turns having a toroidal outline. The end turns are formed to define at least one channel in the end turns that traverses the end turns for increasing a surface area for fluid contact and directing a flow of fluid along the toroidal surface.

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: An automotive motor includes a stator and a rotor disposed within the stator. The automotive motor also includes an endplate attached to the rotor that defines a coolant exit hole, an outer edge, and an array of staggered raised flow disruptors disposed radially between the coolant exit hole and outer edge. The array disrupts flow of coolant as the coolant travels from the coolant exit hole along a surface of the endplate toward the outer edge.

Abstract: An electric machine configured to propel a vehicle includes a stator, a rotor, and an end plate. The stator has end windings that protrude axially therefrom. The rotor is disposed within the stator. The end plate is secured to an axial end of the rotor. The end plate defines a primary chamber, a secondary chamber that is radially outward of the primary chamber, and a first outlet channel that is configured to direct fluid onto the end windings. The primary chamber is in fluid communication with a fluid source and the secondary chamber. The secondary chamber is in fluid communication with the outlet channel.

Abstract: An electric machine configured to propel a vehicle includes a stator, a rotor, and an end plate. The stator has end windings that protrude axially therefrom. The rotor is disposed within the stator. The end plate is secured to an axial end of the rotor. The end plate defines a primary chamber, a secondary chamber that is radially outward of the primary chamber, and a first outlet channel that is configured to direct fluid onto the end windings. The primary chamber is in fluid communication with a fluid source and the secondary chamber. The secondary chamber is in fluid communication with the outlet channel.

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 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: An encasement of an electric machine of an electrified vehicle is provided. The encasement may include a base sidewall, an inner sidewall, and an outer sidewall. The inner sidewall may extend in a circular pattern about the base sidewall. The outer sidewall may extend from the base sidewall and may be spaced apart from the inner sidewall to define a coolant channel at least partially surrounding end windings of a stator of the electric machine. The base sidewall may define features between the sidewalls to promote turbulence of coolant flowing through the coolant channel. The base sidewall may define a meandering trough between the sidewalls to form a predetermined coolant path relative to a location of the end windings.

Abstract: An automotive motor includes a stator and a rotor disposed within the stator. The automotive motor also includes an endplate attached to the rotor that defines a coolant exit hole, an outer edge, and an array of staggered raised flow disruptors disposed radially between the coolant exit hole and outer edge. The array disrupts flow of coolant as the coolant travels from the coolant exit hole along a surface of the endplate toward the outer edge.

Abstract: A vehicle electric machine may include a stator having end windings extending axially from the stator. A rotor may be disposed within the stator and including an endcap having an outer face defining outlets and a furrowed outer periphery with an edge configured to distribute coolant released from the outlets onto the outer face to different axial locations of the end windings during rotation. The furrowed outer periphery may taper toward an in inner flat portion. The outlets may be contained within the inner flat portion. The furrowed outer periphery may be symmetric about any axis perpendicular to and passing through an axis of rotation of the rotor. The outer face may further define channels extending from the outlets to the edge. The channels may be recessed in the outer face. The furrowed outer periphery may define concentric circumferential ridges.

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: An electric machine for a vehicle may include a stator, a rotor, and a coolant channel assembly. The stator may include a core defining a cavity and windings disposed within and partially protruding out of the cavity. The rotor may be sized for disposal within the cavity adjacent the windings. The coolant channel assembly may include a channel wound about the partially protruding windings such that the channel and windings are in thermal communication with one another. The coolant channel may define a circular or rectangular cross-section. The coolant channel may define fins therein to induce turbulence into coolant flowing therethrough. The coolant channel and the windings may be arranged such that the coolant channel assembly directly contacts the windings. The coolant channel assembly may be wound such that a portion of the coolant channel assembly is partially disposed between the plurality of base portions.