Provided are a coil capable of enhancing heat dissipation performance and/or voltage resistance, and a stator and a motor using the coil.

A coil includes a helical structure body made of strip-shaped flat conductors that are continuously joined into a helical form. In the helical structure body, a first turn of helix is separated from a second turn, which is continuous to the first turn, at a preset interval.

A method of manufacturing an armature includes: a step of preparing first segment conductors in which a plurality of end portions, or an end portion and a power terminal member, are electrically connected to each other; a step of disposing leg portions of the first segment conductors and leg portions of second segment conductors in an armature core; and a step of joining the leg portions of the first segment conductors and the leg portions of the second segment conductors to each other.

The invention relates to a method for producing stranded wires, including the steps of applying an insulation layer to lines, separating the insulated lines, individually removing the insulation layer from the separated lines along a partial length of the lines, and bringing the lines together to form a stranded wire, wherein the partial lengths are arranged at the same level at least in sections for the purpose of forming a non-insulated contact region.

A method of manufacturing an armature includes: a step of preparing first segment conductors in which a plurality of end portions, or an end portion and a power terminal member, are electrically connected to each other; a step of disposing leg portions of the first segment conductors and leg portions of second segment conductors in an armature core; and a step of joining the leg portions of the first segment conductors and the leg portions of the second segment conductors to each other.

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.

A method of manufacturing a base winding assembly of a stator. The base winding assembly includes a plurality of conductor loop groups each formed of a plurality of conductor loops that are open on one side, wherein the closed ends of the conductor loops that are open on one side can be arranged at one face of the base assembly and the open ends can be arranged at the opposite face side of the base assembly, wherein the manufacturing of the base winding assembly is done by an additive manufacturing process in which a layer-by-layer application and local solidification of build-up material takes place. Furthermore, a method for manufacturing a stator for an electric machine, as well as a base winding group of a stator and a stator are proposed.

A closed socket brazed joint assembly is provided. The assembly comprises: a first member composed of a first base material; a second member composed of a second base material with a first end composed of a first profile with at least first and second faying surfaces; a socket formed in said first member configured to receive the first end of the second member with a faying surface with at least two portions separated by a first fillet; wherein the socket further is configured such that in a first state before the application of energy to the joint there is a gap with a width between the faying surfaces of the first member and the faying surfaces of the second member; and, in the first state a slug of brazing fill material is disposed between the first end of the second member and at least one faying surface of the socket; and, wherein a second state is created when upon application of energy the brazing fill material melts and flows from between first end of the second member and the at least one faying surface of the socket filling aforesaid gap between the faying surfaces of the first and second members.

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 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 electric machine assembly including a terminal assembly and three terminal lugs is provided. The terminal assembly may include three pairs of terminal leads. Each of the three terminal luges may define a pair of terminal lead through-holes and a pair of opposing radial sides. Each terminal lug may be compressed at one of the sides to deform a respective terminal lug and secure each of the pair of terminal leads within one of the pair of terminal lead through-holes. The assembly may further include a stator disposed within a housing and include end windings. Each of the terminal leads may include a base terminal portion. The terminal assembly and the stator may be arranged with one another such that each base terminal portion is aligned with one of the end windings for securing thereto. The assembly may further include three bridges.