Various embodiments include an electrical insulation system for an electric motor comprising: a laminated core having slots and wire windings; an electrical surface insulation in the slots surrounding individual wires with a potting compound; and an absorbent material between the individual wires and within the wire winding bounded by surface insulation material. The absorbent material took up liquid impregnation resin during the manufacturing process. The liquid impregnation resin has cured and now forms the potting compound.

The invention relates to a stator (16) of an electrical machine (10), to an electrical machine (10), and to a method for producing same, particularly for adjusting movable parts in a motor vehicle, comprising a pole casing (15) to the inner wall (115) of which winding holders (36) carrying electric coils (17) are applied, the winding holders (36) comprising a stator tooth (120) which is formed on a yoke element (118) which is radially applied to the inner wall (115), and an insulating mask (61) is arranged on the winding holder (36), which insulates the electric coil (17) from the winding holder (36), and the insulating mask (61) extends with an axial projection (102) axially over the yoke element (118), the axial projection (102) being radially applied to the inner wall (115) of the pole casing (15) with a shoulder (108) extending in the peripheral direction (2).

A stator of a rotary electric machine comprises a stator core and a stator coil that is wound around the stator core. The stator coil includes a first segment coil, a second segment coil, and a first connecting member that has a first fitting recess portion at a first end of the first connecting member and a second fitting recess portion at a second end of the first connecting member, the first connecting member connecting the first segment coil and the second segment coil by fitting the first segment coil into the first fitting recess portion and by fitting the second segment coil into the second fitting recess portion.

A method for producing a wire coil. Multiple windings of a ply of the wire coil including an insulated wire are wound onto a coil core of the wire core starting from a first winding up to a last winding. The last winding is hooked in an electrically insulating deflection hook of the wire coil which is fixed with respect to the coil core and the wire is deflected by the deflection hook.

In an armature, a plurality of segment conductors, which are joined to each other at a joint portion, are disposed in parallel in the radial direction. An insulating portion is provided on a conductor surface of one segment conductor at a position in the center axis direction corresponding to an adjacent joint portion of a different segment conductor that is adjacent to the one segment conductor in the radial direction. The insulating portion has a second insulation resistance which is higher than a first insulation resistance of an insulating coating of the different segment conductor.

A stator for an electric machine, including a shaped rod winding, wherein the shaped rod winding is formed by a plurality of shaped rods which have connecting points in the region of a winding head, wherein the connection points are surrounded by a casting layer, and wherein a thickness of the casting layer is predetermined by an enveloping element which is arranged on the winding head close to the contour.

Since the shape of the insulating paper is complicated, a forming and bending step of the insulating paper is required, and further there is a step of inserting the insulating paper in the middle of coil forming, which causes a problem of damaging the insulating paper.

A fitting state of an insulating paper 201 into the inter-coil gap has an annular taper shape in which a diameter dimension D1 of an annular opening of the insulating paper 201 on a coil end tip side is long, and a diameter dimension d2 of an annular opening of the insulating paper 201 on a stator end face side on the opposite side is short. The insulating paper 201 is made to follow the tapered shape of the inter-coil gap 140 between an inner peripheral coil 120 and an outer peripheral coil 130, and the insulating paper 201 is fitted in a state inclined from the coil end tip side to the stator end face side with respect to an axial direction of the stator 20. Therefore, bending after the insertion of the insulating paper 201 is reduced, the force of the insulating paper 201 trying to come off to the coil end tip side is suppressed, and it is possible to obtain the effect of preventing the floating and the coming off of the insulating paper 201.

This armature has a core leg portion fixing member that is provided in a slot so as to overlap with a part at a position different from a position in an axial direction corresponding to a joint portion, and that includes a first fixing layer for fixing an armature core and a leg portion.

It is realized that a shape of a bus ring is simplified, and a rotary electric machine is downsized. A coil connecting portion, which is protruded from bus ring maintaining portions to a shaft direction, is provided at a bus ring, and coil terminals are arranged in such a way that the coil terminals are protruded toward an outer side in a diameter direction with respect to the coil connecting portion, and the coil terminals and the coil connecting portion are connected by performing a resistance welding process. Thereby, it is not required that a slit and a bent portion or the like are formed at a tip of the bus ring, and a shape of the bus ring is simplified. Moreover, a welding board for a welding process and a chuck board for a connecting portion are not required, so that a rotary electric machine can be downsized.

A stator assembly for use in an axial flux electric motor includes a plurality of circumferentially-spaced tooth assemblies that each includes a tooth portion and a base portion. The stator assembly also includes a plurality of circumferentially-spaced bridge members that are each configured to engage a pair of circumferentially adjacent base portions.