An electric motor includes a stator, a rotor, and a housing. A slot in a stator core of the stator includes a coil housing and a slot opening that opens the coil housing radially inward. A coil includes a coil end that protrudes in an axial direction from an axial end surface of the stator core. A plastic portion that is integral with the stator core includes a blocking portion that extends in the axial direction so as to block the slot opening, and a cylindrical wall that is coupled with the blocking portion. The cylindrical wall protrudes in the axial direction from the axial end surface of the stator core. The housing defines a coil end cooling channel in which a cooling liquid flows to cool the coil end, at a location radially outward from the cylindrical wall.

A stator assembly including a frame structure having a stator teeth being circumferentially distributed around a longitudinal axis, wherein in between respective two neighboring stator teeth there is formed one stator slot; a winding system having a plurality of electric windings, wherein respectively one electric winding is wound around at least one stator tooth and is partially accommodated within two stator slots and each electric winding comprises an end winding portion which axially protrudes from the frame structure; and an insulation arrangement having a plurality of electric insulation devices, each insulation device surrounding a part of one electric winding is provided. Each insulation device includes an inner insulation portion being accommodated within the respective stator slot and an outer insulation portion protruding from the frame structure and surrounding a part of the respective end winding portion. The outer insulation portion includes an outer surface which includes elevated surface portions.

A method for manufacturing an electromagnetic coil with an intentionally engineered heat flow path is provided. The method includes defining at least one preferential heat flow path for heat to flow for the electromagnetic coil. A coil cartridge in which to encase the electromagnetic coil is designed by selecting dimensions of different portions of the insulating coil cartridge that will result in the at least one preferential heat flow path. The electromagnetic coil is then encased in coil cartridge material to produce an encased electromagnetic coil.

A method and system of assembling hairpin conductors with a stator core, the system and method including: arranging the plurality of hairpin conductors into two or more sub-assembly fixtures, wherein the plurality of hairpin conductors are arranged in the two or more sub-assembly fixtures in two or more layers; activating a retaining mechanism to hold the plurality of hairpin conductors in place within the sub-assembly fixtures; meshing the two or more sub-assembly fixtures together to bring the hairpin conductors into alignment and form a layered conductor assembly; introducing the layered conductor assembly into the stator core by advancing the two or more sub-assembly fixtures in relation to the stator core in alignment with the locations on the stator core for the layered conductor assembly; and at an appropriate timing, deactivating the retaining mechanism to release the layered conductor assembly from the two or more sub-assembly fixtures.

Provided are a stator having insulating paper positioned and fixed using an inexpensive and simple structure, a motor having the stator, and a method for manufacturing the stator. The stator 18 of a motor is provided with a stator core 26 haying a plurality of slots 16, a plurality of coils 32 positioned in the slots, pieces of coil end insulating paper 40 that are positioned between a plurality of coil ends 44 and that insulate the coil ends 44 from each other, and a plurality of pieces of intercoil insulating paper 34 positioned in the slots 16, each of the plurality of pieces of intercoil insulating paper 34 having a projection 38 projecting from an axial end part 36 of the stator core. Each of the pieces of coil end insulating paper 40 has an adhesive part 42, and a plurality of projections 38 are affixed into a single piece of coil end insulating paper 40.

An electric machine includes a stator core defining a plurality of slots, slot liners disposed within the slots and covering inner surfaces of the slots, and windings wound within and between the slots. Each of the slot liners has an end extending away from a face of the stator core and defining a flange that includes a rim in direct contact with the face and a terminating lip that is wider than the rim such that the rim is between the face and the terminating lip.

Rectangular conductor wires are often used in alternator applications requiring a high slot fill to maximize output and efficiency. However for lower output and efficiency applications, round conductor wire may increase cost competiveness in these alternators. A common lamination for a core alternatively accommodates both rectangular conductor wires and round conductor wires for different applications without any other component changes. The lamina has a slot that aligns round wire in a single row within the slot and provides a predetermined clearance from the slot opening. A stator core formed from these laminae has a relatively high slot fill factor when wound with the round wire. The same stator core can be alternatively wound with square wire to increase the slot fill factor even higher. The common lamination results in two stator configurations: a high slot fill version (round wire) and a very high slot fill version (square wire).

A stator includes a plurality of core constituent members arranged side by side in a circumferential direction, each of which has a tooth extending in a radial direction and a pair of core outer extension portion extending in the both circumferential directions from a radial outer end portion of the tooth, and an insulator covering at least a part of the tooth, and a coil wound around the tooth via the insulator. The coil includes a terminal inner coil having a terminal line which is drawn from the radially inner side to the one axial side. The insulator covers the tooth that are circumferentially adjacent to the tooth around which the terminal inner coil is wound. The insulator has a restriction portion so as to restrict the movement of the terminal line of the terminal inner coil.

The present invention provides a motor including a shaft, a rotor coupled to the shaft, and a stator disposed outside the rotor, wherein the stator includes a stator core, insulators disposed on the stator core, coils disposed on the insulators, and insulating members disposed between the insulators in a circumferential direction, the insulator includes a body on which the coil is disposed and a guide extending from one side of the body, the guide includes a protrusion protruding from an inner circumferential surface toward a center of the stator, and a lower portion of the protrusion includes a first inclined surface.

A bobbin structure is inserted into a slot defined in a stator core. The bobbin structure includes a body configured to contact an inner wall of the slot and at least one partition provided inside the body to insulate at least some coils, inserted into the slot so as to be arranged in a plurality of layers, from each other. The body and the at least one partition are formed integrally with each other.