US 12,244,197 B2
Stator with outer diameter bus bar connection
Timothy Beatty, Carmel, IN (US); David Lee Durant, Anderson, IN (US); Ryan J. Jones, Pendleton, IN (US); and Kirk Neet, Noblesville, IN (US)
Assigned to BorgWarner Inc., Auburn Hills, MI (US)
Filed by BorgWarner Inc., Auburn Hills, MI (US)
Filed on Jul. 11, 2022, as Appl. No. 17/862,292.
Claims priority of provisional application 63/221,720, filed on Jul. 14, 2021.
Prior Publication US 2023/0016106 A1, Jan. 19, 2023
Int. Cl. H02K 3/50 (2006.01); H02K 9/22 (2006.01)
CPC H02K 3/50 (2013.01) [H02K 9/223 (2021.01); H02K 2203/09 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A stator for an electric machine, the stator comprising:
a cylindrical core defining an inner cylindrical surface and an outer cylindrical surface with a plurality of slots formed between the inner cylindrical surface and the outer cylindrical surface;
windings positioned on the cylindrical core, the windings including in-slot portions extending through the slots, end turns, and leads, the leads of the windings including a plurality of inner leads associated with conductors in an inner layer of the slots and a plurality of outer leads associated with conductors in an outer layer of the slots; and
a bus bar assembly including a plurality of inner bus bars and a plurality of outer bus bars, the plurality of inner bus bars connected to the plurality of inner leads, and the plurality of outer bus bars connected to the plurality of outer leads, wherein the plurality of outer bus bars are positioned radially outward from the end turns of the windings and radially inward from the outer cylindrical surface, the bus bar assembly further including a first support member comprised of a non-conductive material and a second support member comprised of a non-conductive material, wherein the first support member is distinct from the second support member, wherein at least some of the plurality of inner bus bars extend through the first support member, and wherein at least some of the plurality of outer bus bars extend through the second support member.