US 12,149,136 B2
Stator with printed end turns and methods of making the same
Gabriel Domingues, Noblesville, IN (US); Joshua B. Lahrman, Fishers, IN (US); Matthew R. Conner, Franklin, IN (US); Kirk Neet, Noblesville, IN (US); and David A. Fulton, Anderson, IN (US)
Assigned to BorgWarner Inc., Auburn Hills, MI (US)
Filed by BorgWarner Inc., Auburn Hills, MI (US)
Filed on Apr. 8, 2022, as Appl. No. 17/716,092.
Claims priority of provisional application 63/173,241, filed on Apr. 9, 2021.
Prior Publication US 2022/0329124 A1, Oct. 13, 2022
Int. Cl. H02K 3/28 (2006.01); H02K 3/26 (2006.01); H02K 15/04 (2006.01)
CPC H02K 3/28 (2013.01) [H02K 3/26 (2013.01); H02K 15/0407 (2013.01); H02K 15/0414 (2013.01)] 18 Claims
OG exemplary drawing
 
1. A stator for an electric machine comprising:
a core including a plurality of slots; and
a winding arrangement positioned on the core, the winding arrangement comprising (i) a plurality of axial conductors positioned in the slots of the core, and (ii) a printed winding head including a plurality of 3D printed end turns positioned on an end of the core and a plurality of coil leads, each printed end turn of the plurality of 3D printed end turns extending between a pair of axial conductors, wherein:
each printed end turn of the plurality of 3D printed end turns includes a first segment and a second segment,
the axial conductors and the plurality of 3D printed end turns form a plurality of interlocked coils on the core such that each coil of the plurality of interlocked coils is positioned next to and interlocked with a corresponding adjacent coil in the winding arrangement, and
the first segment of each printed end turn of the plurality of 3D printed end turns is arranged radially inward from the coil lead of the corresponding adjacent coil, and wherein the second segment of each printed end turn of the plurality of 3D printed end turns is arranged radially outward from the first segment of the end turn of the corresponding adjacent coil.