US 12,451,756 B2
Electric machine
Akash Changarankumarath Pradeepkumar, Westland, MI (US); Singar Rathnam, Farmington Hills, MI (US); Joel Hetrick, Ann Arbor, MI (US); and Joshua Simon, Sylvania, OH (US)
Assigned to Ford Global Technologies, LLC, Dearborn, MI (US)
Filed by FORD GLOBAL TECHNOLOGIES, LLC, Dearborn, MI (US)
Filed on Jun. 16, 2022, as Appl. No. 17/842,514.
Prior Publication US 2023/0412037 A1, Dec. 21, 2023
Int. Cl. H02K 5/22 (2006.01); H02K 3/12 (2006.01); H02K 3/28 (2006.01); H02K 3/38 (2006.01); H02K 11/25 (2016.01)
CPC H02K 5/225 (2013.01) [H02K 3/12 (2013.01); H02K 3/28 (2013.01); H02K 3/38 (2013.01); H02K 11/25 (2016.01); H02K 2203/09 (2013.01)] 20 Claims
OG exemplary drawing
 
1. An electric machine comprising:
hairpin windings having a plurality of electrical phases, each electrical phase having a plurality of parallel electrical paths;
a terminal block having,
a plurality of bus bars, each bus bar connected to each parallel electrical path of the one of the electrical phases,
at least one neutral bar connected to each electrical phase, and
an insulating material (i) encapsulating the plurality of bus bars and the at least one neutral bar, (ii) defining a plurality of ports, and (iii) defining a plurality of terminal receiving orifices, wherein (i) each bus bar of the plurality of bus bars is spaced apart from and not connected to other bus bars of the plurality of bus bars within the insulating material, (ii) each bus bar of the plurality of bus bars is spaced apart from and not connected to the at least one neutral bar within the insulating material, (iii) each neutral bar of at least one neutral bar is spaced apart from and not connected to other neutral bars of the at least one neutral bar within the insulating material, (iv) each port extends from a first outer surface of the insulating material to one of the bus bars or to the at least one the neutral bar, (v) each terminal receiving orifice extends from a second outer surface of the insulating material to one of the bus bars, (vi) lead and end hairpins of the hairpin windings, each extending through one of the ports from the first outer surface to a corresponding bus bar or a corresponding neutral bar to connect each electrical path to the corresponding bus bar and the corresponding neutral bar; and
terminal connectors, each (i) extending through one of the terminal receiving orifices, (ii) connected to one of the bus bars, and (iii) protruding outward from the second outer surface of the insulating material.