Abstract: A method of making a stator module for use in a stator assembly of an electric machine includes temporarily supporting a plurality of stator segments in a desired orientation using a temporary support. The desired orientation of the stator segments is a relative orientation of the stator segments within the stator module. A mold is placed around the plurality of stator segments and the mold is filled with a potting material to form a stator module such that the potting material supports the stator segments in their desired orientation. The temporary support is removed.

Abstract: A stator for an electric motor that includes a plurality of stacked laminations and a polymeric shell coupled to the plurality of laminations. Each lamination includes an annular plate having a plurality of notches defined therein. Each notch has an end positioned between the side walls of the annular plate. A plurality of teeth extend from one side wall of the annular plate. Each lamination includes a first slot defined at the first end of each notch and a second slot spaced apart from the first slot, the first slots of the laminations are aligned to define a first plurality of passageways, the second slots of the laminations are aligned to define a second plurality of passageways, and the polymeric shell includes a plurality of support beams that extend through the first plurality of passageways and the second plurality of passageways.

Abstract: A rotating electrical machine includes a rotor and a stator including an annular stator core formed by helically stacking a plurality of core pieces that are connected to each other by connecting portions, the rotor being disposed inside an inner periphery of the stator core. The connecting portions are linearly arranged along a stacking direction of the stator core so that grooves that extend in the stacking direction of the stator core are formed in an outer peripheral surface of the stator core at positions where the connecting portions are provided.

Abstract: A windingly laminated core of a rotary electric machine, having a first number of magnetic poles in total and configured by unit cores, each of which is formed in an arc and thin plate shape and has a second number of magnetic poles, wherein a winding lamination is applied to the unit cores in a circumferential direction and in a spiral manner so as to form a cylindrical shape and a lamination thickness in an axial direction of the winding lamination is set to a predetermined thickness, includes an adjustment unit core having magnetic poles whose number is less than the second number, wherein the adjustment unit core is arranged at a start or an end of the winding lamination, in a circumferential direction, in order to align a rotational phase of the start of the winding lamination to a rotational phase of the end of the winding lamination.

Abstract: An insulating bobbin for disposition between a stator core and a stator winding of a stator of a rotating machine, the stator winding being wound around the stator core by way of the insulating bobbin, the insulating bobbin comprising a coil end section at which an end portion of the stator winding is disposed, a slot side section forming a slot for winding thereon the stator winding, and a corner section having a curved surface and connecting between the coil end portion and the slot side portion, the corner section having a first radius of curvature at a side closer to the coil end section and a second radius of curvature at a side closer to the slot side section, the second radius of curvature being larger than the first radius of curvature.

Abstract: A stamping step of forming a plurality of band-shaped core sheets (11), (12) having arc-shaped segment core sheets (15), (15a), the adjacent segment core sheets (15), (15a) connected together by narrow-width connecting portions (16), (16a) provided therebetween, the segment core sheets (15), (15a) having a plurality of pole sections (13), (14), (13a), (14a) protruding radially outward; and an annular shape forming step of winding the plurality of band-shaped core sheets (11), (12) in a spiral form while bending the band-shaped core sheets (11), (12) at the connecting portions (16), (16a) and superimposing the pole sections (13), (14), (13a), (14a) vertically one on another, thereby laminating the band-shaped core sheets (11), (12); wherein in the stamping step, notches (23a), (23) to be positioned in correspondence with the connecting portions (16), (16a) bent in the annular shape forming step are formed at radially outward sides of joining portions (22a), (22), the joining portions joining the adjacent pole