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.

A stator of an electric machine includes a laminated core having slots for receiving windings of a multiphase winding system. The windings have winding ends, which are encased with an insulator across a partial length. In order to encase the winding ends with the insulator, a strand of a thermoplastic material is extruded onto the winding ends via a nozzle. During extrusion, the nozzle is moved relative to the winding end along the longitudinal extent thereof and an oscillating movement of the nozzle transversely to the longitudinal extent of the winding end overlays the movement along the longitudinal extent. As a result the thermoplastic material lies on the winding end and around the respective winding end in the form of loops.

A stator of an electric machine includes a laminated core having slots for receiving windings of a multiphase winding system. The windings have winding ends, which are encased with an insulator across a partial length. In order to encase the winding ends with the insulator, a strand of a thermoplastic material is extruded onto the winding ends via a nozzle. During extrusion, the nozzle is moved relative to the winding end along the longitudinal extent thereof and an oscillating movement of the nozzle transversely to the longitudinal extent of the winding end overlays the movement along the longitudinal extent. As a result the thermoplastic material lies on the winding end and around the respective winding end in the form of loops.

The present invention relates to a coil module for an electric machine, comprising at least one coil disc comprising a coil carrier made of an electrically insulating material and a plurality of individual windings made of an electrically conductive material and being circumferentially arranged on the coil disc around a center of the coil disc. Each of the windings comprises two active regions extending radially from the center and two passive regions extending tangentially at its radially outer and inner edges, wherein, in a top view of the coil disc, the active regions of different windings do not overlap each other, but each passive region of one of the windings partially overlaps the corresponding passive regions of the two directly adjacent windings. In the active regions, the respective winding in cross-section has a greater thickness in the axial direction than in the passive regions.

A rotating electrical machine includes an armature that includes a multiphase armature winding. The multiphase armature winding includes winding segments. Each of the winding segments is comprised of a multiply-wound conductive wire member. The winding segments are arranged at predetermined intervals in a circumferential direction of the rotating electrical machine. Each of the winding segments has an end. The ends of the winding segments are collected at a predetermined connection point. The collected ends of the winding segments are connected to a neutral point or an input/output terminal of a power converter.

A brushless DC motor includes a stator, a rotor, and motor terminals mounted on the stator. Each motor terminal includes a planar portion extending circumferentially from the end insulator, a wire-receiving member extending from a first end of the planar portion and folded over an outer surface of the planar portion away from the center axis of the stator at an angle of less than 90 degrees, and a tab portion extending from a second end of the planar portion parallel to the center axis of the stator. A circuit board is disposed adjacent the motor including power switches mounted thereon for energizing the stator windings. Slots are formed in the circuit board to align with and securely receive the tab portions of the motor terminals, thus electrically connecting the motor terminals to the power switches.

A stator (1) for an electric motor, including; a plurality of pins (11, 12, 13, 14, 21, 22, 23, 24, 31, 32, 33, 34) which are arranged on at least two concentric circles; and an interface (10, 20, 30) with at least one contact face (19, 29, 39), which is connected to two electrically conductive legs (10a, 10b, 20a, 20b, 30a, 30b) and is supported by the legs, wherein the legs are connected to at least one pin on different concentric circles.

A stator (1) for an electric motor, including; a plurality of pins (11, 12, 13, 14, 21, 22, 23, 24, 31, 32, 33, 34) which are arranged on at least two concentric circles; and an interface (10, 20, 30) with at least one contact face (19, 29, 39), which is connected to two electrically conductive legs (10a, 10b, 20a, 20b, 30a, 30b) and is supported by the legs, wherein the legs are connected to at least one pin on different concentric circles.

Stator and method for producing a stator for an electrical machine, comprising a stator main body (34) which has radial stator teeth (14) for receiving coils (17) of an electrical winding and, on an end side of the stator main body (34), has an insulating lamination (40) with receiving pockets (46) for insulation-displacement terminal elements (70), wherein the coils (17) are wound by means of a winding wire which is inserted into the receiving pockets (46), wherein an interconnection plate (52) has annular conductors (84) on which in each case a plurality of insulation-displacement terminal elements (70) are arranged, which insulation-displacement terminal elements axially engage into the receiving pockets (46) in order to make electrical contact with the winding wire, wherein the interconnection plate (52) is manufactured from plastic and has annular grooves (59) which are open axially at the bottom and into which the annular conductors (84) are inserted.

A system includes a pair of terminal leads joined together. An insulative sleeve is wrapped around the pair of terminal leads. Lacing binds around the insulative sleeve. Cured epoxy can encase the insulative sleeve and lacing. The insulative sleeve can include fiberglass. The insulative sleeve can be wrapped more than 360° around the pair of terminal leads so that a first edge of the insulative sleeve is tucked under a second edge of the insulative sleeve.