Patent ID: 11876405
Assignee: HAMILTON SUNDSTRAND CORPORATION
Field: Electrical machinery, apparatus, energy (Electrical engineering)
Classification: CPC H | IPC H

Claim 9:
10. A method of forming a stator of an electric motor, comprising:
installing a plurality of stator windings to a stator core, the stator core including a plurality of core teeth defining a plurality of tooth gaps therebetween, the plurality of stator windings including:
a plurality of core segments extending along the plurality of tooth gaps; and
a plurality of end turn segments connecting adjacent core segments; and

installing a plurality of non-electrically conductive cooling channels through the plurality of core teeth, the cooling channels configured to direct a cooling fluid flow therethrough to cool the plurality of stator windings;
securing an inlet header including a fluid inlet to the plurality of cooling channels at a first axial end of the stator; and
securing an outlet header including a fluid outlet to the plurality of cooling channels at a first axial end of the stator;
wherein one or more of the inlet header or the outlet header are formed from a polymeric material;
wherein the plurality of end turn segments are curvilinear; and
wherein one or more of the inlet header or the outlet header is conformally shaped to the curvilinear end turn segments to cool the plurality of end turn segments;
wherein the plurality of cooling channels and one or more of the inlet header or the outlet header are formed together as a single unitary component;
wherein the inlet header includes:
a first header arm extending circumferentially in a first direction from the fluid inlet and terminating at a first arm end; and
a second header arm extending circumferentially in a second direction opposite the first direction from the fluid inlet and terminating at a second arm end.