An electric machine includes a plurality of printed layers arranged to form a stator having an outer periphery and teeth extending radially inward from the outer periphery. Each of the printed layers includes discrete portions of metal and discrete portions of insulation. The discrete portions of insulation define a contiguous network of insulative boundaries separating discrete cells formed by the discrete portions of the metal. A volume of the discrete cells within the outer periphery is greater than a volume of the discrete cells within the teeth such that a reluctance of the teeth is greater than a reluctance of the outer periphery.

A motor core assembly and a manufacturing method for the motor core assembly include a permanent magnet inside a motor that may be recovered, in its original state without damage and at a low cost, from a motor to be disposed of together with a device when the device to which the motor is applied is disposed of in a state in which the permanent magnet wrapped with an injection part is inserted into a rotor core. Accordingly, the number of manufacturing processes and the cost may be reduced.

A motor core assembly and a manufacturing method for the motor core assembly include a permanent magnet inside a motor that may be recovered, in its original state without damage and at a low cost, from a motor to be disposed of together with a device when the device to which the motor is applied is disposed of in a state in which the permanent magnet wrapped with an injection part is inserted into a rotor core. Accordingly, the number of manufacturing processes and the cost may be reduced.

Presented are oleophilic surface treatments for electric machines, methods for making/using such electric machines, and vehicles employing traction motors having stator windings with oleophilic treatments on select surfaces. An electric machine includes an outer housing with a direct-cooling thermal management system fluidly connected to the housing to circulate thereto a coolant fluid. A stator assembly, which is attached to the housing, includes a stator core with one or more electromagnetic windings mounted to the stator core. A rotor assembly is movably mounted to the hosing adjacent the stator assembly. The rotor assembly includes a rotor core with one or more magnets mounted to the rotor core spaced, e.g., across an air gap, from the winding(s). Select components of the stator assembly have a target surface with an oleophilic surface treatment that enlarges the target surface's wetted area and increases a coolant mass of the coolant fluid contacting the target surface.

Presented are oleophilic surface treatments for electric machines, methods for making/using such electric machines, and vehicles employing traction motors having stator windings with oleophilic treatments on select surfaces. An electric machine includes an outer housing with a direct-cooling thermal management system fluidly connected to the housing to circulate thereto a coolant fluid. A stator assembly, which is attached to the housing, includes a stator core with one or more electromagnetic windings mounted to the stator core. A rotor assembly is movably mounted to the hosing adjacent the stator assembly. The rotor assembly includes a rotor core with one or more magnets mounted to the rotor core spaced, e.g., across an air gap, from the winding(s). Select components of the stator assembly have a target surface with an oleophilic surface treatment that enlarges the target surface's wetted area and increases a coolant mass of the coolant fluid contacting the target surface.

A stator, of a rotating electrical machine, includes a core including a plurality of teeth and a slot formed between the teeth, and a plurality of coils inserted into the slot and fixed with varnish, in which the plurality of coils is disposed side by side in a radial direction in the slot, and the varnish is most applied to at least an innermost diameter side coil among the plurality of coils in the slot.

A brushless motor is provided that includes a stator assy and a rotor. The stator assy includes a stator, a housing that has a space where the stator is disposed, and an insulating resin disposed in the space. The insulating resin fixes the housing to the stator. The housing includes a first housing member and a second housing member. The insulating resin also fixes first housing member to the second housing member.

A brushless motor is provided that includes a stator assy and a rotor. The stator assy includes a stator, a housing that has a space where the stator is disposed, and an insulating resin disposed in the space. The insulating resin fixes the housing to the stator. The housing includes a first housing member and a second housing member. The insulating resin also fixes first housing member to the second housing member.

A varnish injection system includes a rotatable mount, an electric motor supported by the rotatable mount, the electric motor including a stator and a wire, and a varnish injector including a base and a nozzle extending from the base, the nozzle defining an axis extending vertically therethrough. The electric motor is rotatable by the rotatable mount to a nonzero angle relative to the axis extending vertically through the nozzle. The nozzle is arranged to deposit varnish into a gap defined between the stator and the wire when the rotatable mount rotates the electric motor to the nonzero angle.

A varnish injection system includes a rotatable mount, an electric motor supported by the rotatable mount, the electric motor including a stator and a wire, and a varnish injector including a base and a nozzle extending from the base, the nozzle defining an axis extending vertically therethrough. The electric motor is rotatable by the rotatable mount to a nonzero angle relative to the axis extending vertically through the nozzle. The nozzle is arranged to deposit varnish into a gap defined between the stator and the wire when the rotatable mount rotates the electric motor to the nonzero angle.