An axial flux motor includes a rotor and a stator, and the stator is at least partially overlapped with the rotor in the axial direction. The stator includes a soft magnetic material body, a plurality of conductor wires, a housing, and a thermosetting insulating material. The soft magnetic material body has a plurality of slots. The conductor wires pass through the slots in a radial direction to form a plurality of windings. The housing surrounds the soft magnetic material body. The thermosetting insulating material is connected between the soft magnetic material body and the housing, and filled into gaps of the conductor wires and the slots.

Provided is method for manufacturing a stator for a rotary electric machine. The method includes: preparing a workpiece in which a plurality of coil pieces forming a stator coil is attached to a stator core, the workpiece having tips of one of the coil pieces and another of the coil pieces joined together on one axial end side; immersing, after the preparation step, the workpiece in a bath of a liquid resin material so that an impregnation target area including a joint between the tips is immersed; and rotating, after the immersion step, the workpiece at a raised position of the workpiece where the impregnation target area is separated from the bath. The rotating step includes rotating the workpiece about a workpiece central axis corresponding to a stator central axis in a posture of the workpiece in which the impregnation target area is oriented in a direction intersecting a vertical direction.

Provided is method for manufacturing a stator for a rotary electric machine. The method includes: preparing a workpiece in which a plurality of coil pieces forming a stator coil is attached to a stator core, the workpiece having tips of one of the coil pieces and another of the coil pieces joined together on one axial end side; immersing, after the preparation step, the workpiece in a bath of a liquid resin material so that an impregnation target area including a joint between the tips is immersed; and rotating, after the immersion step, the workpiece at a raised position of the workpiece where the impregnation target area is separated from the bath. The rotating step includes rotating the workpiece about a workpiece central axis corresponding to a stator central axis in a posture of the workpiece in which the impregnation target area is oriented in a direction intersecting a vertical direction.

Various embodiments of the teachings herein include a method of ascertaining a progression of curing on application of an electrical insulation layer of an insulation material in a liquid state to an electrical product. An example includes: providing a temperature progression that the electrical product undergoes in the course of application and curing of the insulation layer; providing a reaction model of the insulation material to give a progression of curing of the insulation material on the basis of a temperature progression as input parameter and modeled on the basis of measured enthalpies of reaction of the insulation material at two different heating rates; and ascertaining the progression of curing using the reaction model with the temperature progression.

A conductor and method of fabricating a conductor for a high voltage rotating machine. The conductor includes a conductor stack and conductor insulation surrounding the conductor stack. The conductor insulation includes a stress control coating. The stress control coating includes an inner layer including semiconducting paint, a middle layer including semiconducting tape, and an outer layer including semiconducting paint.

A conductor and method of fabricating a conductor for a high voltage rotating machine. The conductor includes a conductor stack and conductor insulation surrounding the conductor stack. The conductor insulation includes a stress control coating. The stress control coating includes an inner layer including semiconducting paint, a middle layer including semiconducting tape, and an outer layer including semiconducting paint.

A coil system for a motor including a coil formed from strips and including straight sections passing through apertures of the motor, and, for each straight element of the coil passing through the same aperture, a shielding system with at least one first band and at least one second band arranged on either side of the elements, in which the strips are electrically connected to an electrical power source, in which two successive strips in the stack are electrically insulated from each other, and in which each band that is placed next to a strip of the coil is electrically insulated from the strip. With such an arrangement, the losses are reduced.

A coil system for a motor including a coil formed from strips and including straight sections passing through apertures of the motor, and, for each straight element of the coil passing through the same aperture, a shielding system with at least one first band and at least one second band arranged on either side of the elements, in which the strips are electrically connected to an electrical power source, in which two successive strips in the stack are electrically insulated from each other, and in which each band that is placed next to a strip of the coil is electrically insulated from the strip. With such an arrangement, the losses are reduced.

A composite wire bundle for a stator winding, a stator including a composite wire bundle, and a method of forming a composite wire bundle. The composite wire bundle includes a plurality of copper wires, wherein each of the plurality of copper wires include a first surface. The composite wire bundle also includes a copper-graphene multilayer composite applied to the first surface of each of the plurality of copper wires, wherein the copper-graphene multilayer composite includes a second surface. Further, the composite wire bundle includes a fluoropolymer matrix formed around the second surfaces and a jacket encapsulating the fluoropolymer matrix.

A composite wire bundle for a stator winding, a stator including a composite wire bundle, and a method of forming a composite wire bundle. The composite wire bundle includes a plurality of copper wires, wherein each of the plurality of copper wires include a first surface. The composite wire bundle also includes a copper-graphene multilayer composite applied to the first surface of each of the plurality of copper wires, wherein the copper-graphene multilayer composite includes a second surface. Further, the composite wire bundle includes a fluoropolymer matrix formed around the second surfaces and a jacket encapsulating the fluoropolymer matrix.