Patent ID: 11444497

Abstract:
A stator for an electric machine is fabricated by assembling a core and first and second winding assemblies. The first winding assembly (FWA) is fabricated by a 3D printing process and includes a plurality of U-shaped conductors (hairpins) having respective end-turns arranged in mutually axially-nested relationship to each other to form a ring, and further having two uprights disposed in one of the slots of the core. End-turns connect respective pairs of the uprights and are disposed adjacent to an end surface of the core, distal ends of the uprights projecting axially beyond an opposite end surface of the core. The second winding assembly (SWA) includes a plurality of bridges forming a second ring Opposite ends of each bridge define terminals that mate with ends of the uprights. The SWA further includes an electrically non-conductive casing in which at least one of the bridges is embedded.