Abstract: A method of inserting coils in slots of a stator is provided. The method includes interleaving a first set of first phase windings and a first set of second phase windings on an insertion tool. The method also includes activating the insertion tool to radially insert the first set of first phase windings and the first set of second phase windings in the slots of the stator. In one embodiment, interleaving the first set of first phase windings and the first set of second phase windings on the insertion tool includes forming the first set of first phase windings in first phase openings defined in the insertion tool, and forming the first set of second phase windings in second phase openings defined in the insertion tool.

Abstract: A rotor assembly comprising: a circular iron core having a top and bottom side spaced from each other; extruded aluminum bars inserted into and around the circumference of the circular iron core; and a pair of extruded circular end rings attached to the top and bottom of the iron core. The circular end rings are cut from an elongated extruded member and are configured to have a plurality of openings configured to align with and receive a portion of the extruded aluminum bars when they are inserted into the iron core. A manufacturing process for manufacturing the rotor assembly is also described.

Abstract: A stator core and method of making, the stator core and a plurality of separate poles are formed from lamination segments that are each stamped from a single piece of stock. The core includes a plurality of fixed pole segments and a plurality of engagement openings configured to receive and engage the separate pole segments. The method of making the stator core allows for maximum use of the material from which the laminations of the stator are stamped as well as an efficient use of the available space within the stator core. In addition, the method allows for maximum copper slot fill.

Abstract: A rotor assembly comprising: a circular iron core having a top and bottom side spaced from each other; extruded aluminum bars inserted into and around the circumference of the circular iron core; and a pair of extruded circular end rings attached to the top and bottom of the iron core. The circular end rings are configured to have a plurality of openings configured to align with and receive a portion of the extruded aluminum bars when they are inserted into the iron core. A manufacturing process for manufacturing the rotor assembly is also described.

Abstract: A catalytic converter is constructed by measuring a substrate to be placed within the outer shell or can, wrapping the substrate in a selected mat and loading the package (mat and substrate) into the can. The can is larger than it will be at completion of manufacture to render such loading easier. Subsequent to loading, the measurement of the substrate is used to direct the degree to which the can is reduced in outside dimension such that a selected annulus is created between the substrate and can, said annulus being occupied by said mat.

Abstract: A segmented core for an electric machine includes segments stamped from coated electric steel. The segments each have a first end, a second end, and winding openings. A predetermined number of segments are placed end-to-end to form layers. The layers are stacked such that each of the layers is staggered from adjacent layers by a predetermined rotation angle. The winding openings of each of the layers are in vertical alignment with the winding openings of the adjacent layers. The stack of layers is secured to form the segmented core.

Abstract: A method of inserting coils in slots of a stator is provided. The method includes interleaving a first set of first phase windings and a first set of second phase windings on an insertion tool. The method also includes activating the insertion tool to radially insert the first set of first phase windings and the first set of second phase windings in the slots of the stator. In one embodiment, interleaving the first set of first phase windings and the first set of second phase windings on the insertion tool includes forming the first set of first phase windings in first phase openings defined in the insertion tool, and forming the first set of second phase windings in second phase openings defined in the insertion tool.

Abstract: A segmented core for an electric machine includes segments stamped from coated electric steel. The segments each have a first end, a second end, and winding openings. A predetermined number of segments are placed end-to-end to form layers. The layers are stacked such that each of the layers is staggered from adjacent layers by a predetermined rotation angle. The winding openings of each of the layers are in vertical alignment with the winding openings of the adjacent layers. The stack of layers is secured to form the segmented core.

Abstract: Described is a rotor assembly comprising: a circular iron core having a top and bottom side spaced from each other; extruded aluminum bars inserted into and around the circumference of the circular iron core; and a pair of extruded circular end rings attached to the top and bottom of the iron core and positioned. A manufacturing process for manufacturing the rotor assembly is also described.

Abstract: An intumescent catalyst mounting mat is provided by cutting a single piece of mat into a desired profile and cutting a slit about 1/2 way through the thickness of the mat at a selected fold line. The mat is then easily folded upon itself to create a double thickness mat that is already secured to the next layer and may have any desired profile.

Abstract: A catalytic converter structure is provided for purifying exhaust gases from an internal combustion engine. The catalytic converter structure includes a cylindrical catalyst substrate; a first cylindrical tube covering a first end of the substrate; a second cylindrical tube covering a second end of the substrate; a support mat surrounding a central portion of the substrate and portions of the first and second cylindrical tubes; and a cylindrical housing within which the substrate, first and second cylindrical tubes and the support mat are located. The structure requires few components, is easy to tool and easy to adapt to different engine implementations.

Abstract: An end cone assembly for a catalytic converter includes a larger formed sheet metal outer cone and a smaller formed sheet metal inner cone forming a dual wall cone assembly. The cones have large ends and connecting conical walls which are configured like those of a prior art end cone and are formable by the same tooling. The cones have inner ends connected with the conical walls that are modified to connect with smaller diameter exhaust pipes and require modified tooling to make. The prior art cones have cylindrical small ends that are telescoped together and locked by dimples. The small end of the new inner cone varies from the conical configuration of its respective wall in, first, curving outward toward an axial direction, second, curving inward toward a radial direction and, third, curving outward to an essentially axial direction defining a generally cylindrical outer end.

Abstract: A catalytic converter structure comprising: cylindrical catalyst substrate; a first cylindrical tube covering a first end of the substrate; a second cylindrical tube covering a second end of the substrate; a support mat surrounding a central portion of the substrate and portions of the first and second cylindrical tubes; and a housing having a cylindrical shape, within which the substrate, first and second cylindrical tubes and the support mat are located, wherein the housing has a central body and first and second housing ends, wherein the housing ends each have a first diameter less than a second diameter of the central body, wherein the first and second housing ends engage the first and second cylindrical tubes, respectively. The structure requires few components, is easy to tool and easy to adapt to different engine implementations.