An electric motor stator includes a magnetic circuit having a plurality of radial polar protuberances. The stator has, for all or some of said protuberances, a set of conductive zones in the general shape of a U, disposed around the protuberance, and the ends of each of the conductive zones are located in the vicinity of a common plane. The stator also has at least one connection component including a plurality of conductive tracks connected to distinct ends of said conductive zones, so as to define a DC electric circuit forming a winding around one or more radial polar protuberances.

Methods of winding a serpentine pattern of a stator coil and structures made from the methods. In one embodiment, a method forms a serpentine winding from a bundle of wires with a first end and a second end, then joins a first group of in-hand conductors of the second end to a second group of in-hand conductors of the first end, the result of which electrically connects a first turn to a second turn. The successive turns of the coil are connected in the same manner. In one embodiment, a method forms a multiple phase serpentine winding, such as three-phases, with coplanar radial conductors. In one embodiment, a method includes a method of forming a serpentine winding on one or more layers of a printed circuit board (PCB). In one embodiment, a method uses plated slots adjacent one or more radial torque inducing conductors to electrically connect the radial conductors of one layer to one or more corresponding radially torque inducing conductor(s) on at least one other layer. In one embodiment, a method removes the electrically conductive material on at least one end of the plated slot in order to reduce looping electrical currents. In one embodiment, a method removes the electrically conductive material from each end of a plated slot so that a pair of radially torque inducing conductors are electrically connected in series.

A method for manufacturing a stator of a waterproof motor includes disposing a first assembly in a mold where the first assembly includes a coil unit wound around an iron core assembly and filling the mold with a thermosetting plastic which forms a housing after curing. The housing envelops the coil unit and the iron core assembly. A recess is formed at one end of the housing. The method further includes disposing a second assembly in the recess of the housing where the second assembly includes a circuit unit and filling the recess of the housing with a waterproof glue which envelops the circuit unit after curing. According to the above, the stator of the waterproof motor is formed.

A method of manufacturing an armature includes: a step of placing a bonding agent on bonding surfaces of the distal ends of a plurality of segment conductors; a step of placing the plurality of segment conductors on an armature core; a step of bonding the distal ends to each other; and a step of increasing a viscosity of the bonding agent placed on the distal ends, after the step of placing the bonding agent on the distal ends, and before the step of bonding the distal ends to each other.

An electrical distribution member includes a plurality of electrical conducting wires made of a solid wire. The electrical conducting wires each include an electrical conducting body, and a coating layer provided over a surface of that electrical conducting body, while removed therefrom over a respective predetermined length including a joining portion. The electrical conducting wires include at least one first electrical conducting wire having a joining portion extending in an axial direction of a stator core, and at least one second electrical conducting wire having a joining portion bent in relation to a radial direction of the stator core in such a manner as to follow a circumferential direction of the stator core. The predetermined length of the second electrical conducting wire with the coating layer removed therefrom is longer than the predetermined length of the first electrical conducting wire with the coating layer removed therefrom.

An electric machine comprises a rotor and a stator, wherein the stator comprises a stator body which carries at least one respective winding of at least one phase, wherein the winding of the respective phase or at least one of the windings of the respective phase is conductively connected to a respective contact bridge, which connects the respective winding to an associated power source and/or drain, wherein the respective winding and the contact bridge connected to it each end in a conductor section which extends away from the stator body in the axial direction of the electric machine, these conductor sections being conductively connected to one another, wherein a fixing section of the respective contact bridge is arranged stationary with respect to a housing accommodating the stator by being fixed by an insulation element or directly, on the one hand, to the housing itself and/or, on the other hand, to the power source and/or drain, which, in turn, is fixed to the housing.

A conductor shaping apparatus includes a driving device that relatively rotates an upper die and a lower die and integrally rotates the upper and lower dies with respect to a shaping member. The driving device rotates one of the upper and lower dies in a direction from an edgewise bent portion to a distal end of a conductor so as to separate the one of the upper and lower dies from the other. One of the upper and lower dies includes a supporting surface configured to support a side surface of an end portion of the conductor as the edgewise bent portion is formed in the end portion, and a guide surface that is formed to intersect the support surface. The guide surface extends away from the end portion of the conductor in a direction opposite to a bent direction of a flatwise bent portion closest to the edgewise bent portion as it extends away from the supporting surface on an opposite side of a rotational axis.

An electric machine winding assembly including a stator and windings is provided. The stator may define a central axis. The windings may extend from the stator and each may include a pair of conductor ends. Each conductor end may include a minor side and a major side. The windings are arranged with the stator such that each of the major sides are aligned along a circumferential conductor axis relative to the central axis to facilitate welding adjacent conductor ends to one another. Each of the windings may further include two portions defining a U shape. Each of the two portions may include a lower portion, a mid-portion, and an upper portion. One of the mid-portions may include a first bend defining a twist shape to orient the major sides of one of the pair of conductor ends along the circumferential conductor axis.

A method for manufacturing a stator of a waterproof motor includes disposing a first assembly in a mold where the first assembly includes a coil unit wound around an iron core assembly, and filling the mold with a thermosetting plastic which forms a housing after curing. The housing houses the coil unit and the iron core assembly. A recess is formed at one end of the housing. The method further includes disposing a second assembly in the recess of the housing where the second assembly includes a circuit unit, and filling the recess of the housing with a waterproof glue which envelopes the circuit unit after curing. According to the above, the stator of the waterproof motor is formed.

A rotary electric machine armature that includes a cylindrical armature core and a coil wound around the armature core, wherein: the coil is formed by joining a plurality of segment conductors to each other; the segment conductors have respective conductor side portions that extend along the axial direction; the conductor side portions are provided with respective joint portions; the joint portions have respective facing surfaces; the joint portions of a pair of the segment conductors are joined to each other with the facing surfaces of the joint portions facing each other; and a facing surface of the facing surfaces is formed so as to have a portion that faces a radial direction and so as not to have portions that overlap each other as viewed in the radial direction over the entire facing surface.