US 12,136,856 B2
Hairpin conductor for an electric motor stator and method of forming the hairpin conductor
John D. Campbell, Rochester Hills, MI (US); Edward L. Kaiser, Orion, MI (US); Elizabeth Pepper, Royal Oak, MI (US); and Caroline Bolt, Royal Oak, MI (US)
Assigned to GM Global Technology Operations LLC, Detroit, MI (US)
Filed by GM GLOBAL TECHNOLOGY OPERATIONS LLC, Detroit, MI (US)
Filed on Jul. 6, 2022, as Appl. No. 17/858,214.
Prior Publication US 2024/0014719 A1, Jan. 11, 2024
Int. Cl. H02K 15/06 (2006.01); H02K 1/16 (2006.01); H02K 3/28 (2006.01); H02K 15/085 (2006.01)
CPC H02K 15/064 (2013.01) [H02K 1/16 (2013.01); H02K 3/28 (2013.01); H02K 15/085 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method of forming a hairpin conductor, comprising:
providing two straightened wire segments each having a predetermined length, respective first and second ends, and a respective middle region located between the respective first and second ends;
stripping a respective portion of each of the two wire segments at the respective first and second ends of each wire segment to produce respective first and second stripped end portions thereat and/or at the respective middle region of each wire segment to produce a stripped middle portion thereat;
disposing the two wire segments beside each other such that their first ends are disposed proximate each other and their second ends are disposed proximate each other;
welding the first stripped end portions to each other and the second stripped end portions to each other and/or the stripped middle portions to each other, to produce a welded wire assembly; and
bending the welded wire assembly while maintaining the two wire segments beside each other to form the hairpin conductor, wherein the hairpin conductor has a primary bend in the middle regions of the two wire segments to form an apex thereat, and first and second secondary bends in the two wire segments nearer to the apex than to the first and second ends to form respective first and second shoulders thereat.