US 12,476,507 B2
Conductive composite stator unit for an electric motor of a vehicle
Yi Liu, Troy, MI (US); Qigui Wang, Rochester Hills, MI (US); Huaxin Li, Rochester Hills, MI (US); Kestutis A. Sonta, Warren, MI (US); and Daniel J. Wilson, Linden, MI (US)
Assigned to GM GLOBAL TECHNOLOGY OPERATIONS LLC, Detroit, MI (US)
Filed by GM Global Technology Operations LLC, Detroit, MI (US)
Filed on Jun. 19, 2023, as Appl. No. 18/337,192.
Prior Publication US 2024/0421645 A1, Dec. 19, 2024
Int. Cl. H02K 3/02 (2006.01); H02K 1/16 (2006.01); H02K 3/30 (2006.01)
CPC H02K 3/02 (2013.01) [H02K 1/16 (2013.01); H02K 3/30 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A conductive composite stator unit for an electric motor of a vehicle, the stator unit comprising:
a stator core comprising a body having a first core end and an opposing second core end defining a longitudinal axis, the body having an inner radial surface extending from the first core end to the second core end relative to the longitudinal axis, the inner radial surface having a plurality of inner walls inwardly extending from the first core end to the second core end defining open slots formed between respective inner walls from the first core end through the second core end;
a plurality of conductive bars extending from the first core end to the second core end, each conductive bar comprising a central portion and an outer layer disposed thereabout for electrical current to flow therethrough relative to the longitudinal axis, each conductive bar comprising a straight portion disposed in one of the slots such that the respective conductive bar is in contact with the stator core, each straight portion having a first radial end at the first core end and a second radial end at the second core end, the first radial end extending from the stator core to a first turn portion and the second radial end extending from the stator core to a second turn portion, the outer layer comprising at least two copper-graphene (Cu-Gr) layers, each Cu-Gr layer comprising a copper layer and a graphene layer; and
an insulator layer disposed about each of the plurality of conductive bars,
wherein the outer layer further comprises a metal substrate having a first side and an opposite second side, the at least two Cu-Gr layers being a first Cu-Gr multilayer composite disposed on the first side of the metal substrate, the outer layer further comprising a second Cu-Gr multilayer composite disposed on the second side of the metal substrate.