Electric machine system having winding arrangement of cooling channels

Abstract

An electric machine includes a stator core having a first axial end and a second axial end separated along a longitudinal axis. The stator core has a slot extending between a first axial end and a second axial end. The electric machine also includes a plurality of winding members. The plurality of winding members includes a plurality of longitudinal segments received in the slots and extending between the first axial end and the second axial end. Each of the plurality of longitudinal segments has a non-circular cross-sectional profile. The plurality of longitudinal segments are disposed in an abutting arrangement to define fluid passages within the slot and between adjacent ones of the plurality of longitudinal segments. A fluid passage extends between a first axial end and a second axial end of the stator core.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to electric machines, and more particularly to electric machine systems having winding arrangements with cooling passages. BACKGROUND

[0002] Electric machines, such as electric motors, electric generators, and combined motor / generators, are provided for a variety of uses. For example, electric traction motors are proposed for use in electric vehicles, locomotives, and the like.

[0003] Some electric machine systems can generate heat during operation, can be operated in high temperature environments, and the like. Elevated temperatures can impede performance and / or cause other disadvantages. Accordingly, electric machine systems are proposed that include cooling features. However, providing such cooling features remains challenging. If these cooling features are included, there can be an increase in cost, number of parts, complexity of the device, size, bulk, and / or weight disadvantages.

[0004] Accordingly, there remains a need for an electric machine system that provides effective cooling. There remains a need for such an electric machine system in which the cooling features are provided in a relatively compact, lightweight package. There also remains a need for such an electric machine system that also provides high manufacturing efficiency to reduce cost and manufacturing time. SUMMARY

[0005] The summary is provided to describe selected concepts in a simplified form as a prelude to the detailed description that is to follow. The summary is not intended to identify key or essential features of the claimed subject matter, nor is it meant to be used as an aid in determining the scope of the claimed subject matter.

[0006] In one embodiment, an electric machine is disclosed that includes a stator core having a first axial end portion and a second axial end portion separated along a longitudinal axis. The stator core has slots extending between the first axial end portion and the second axial end portion. The electric machine also includes a plurality of winding members. The plurality of winding members includes a plurality of longitudinal segments received in the slots and extending between the first axial end portion and the second axial end portion. Each longitudinal segment of the plurality of longitudinal segments has a non-circular cross-sectional profile. The plurality of longitudinal segments are disposed in an abutting arrangement to define fluid passages within the slots and between adjacent longitudinal segments of the plurality of longitudinal segments. The fluid passages extend between the first axial end portion and the second axial end portion of the stator core.

[0007] In another embodiment, an electric motor system includes a housing defining a motor cavity and an electric motor received in the motor cavity. The electric motor includes a stator core having a first axial end portion and a second axial end portion separated along a longitudinal axis. The stator core has a slot extending between the first axial end portion and the second axial end portion. The electric motor includes a plurality of winding members. The plurality of winding members includes a plurality of longitudinal segments received in the slot and extending between the first axial end portion and the second axial end portion. Each of the plurality of longitudinal segments has a non-circular cross-sectional profile. The plurality of longitudinal segments are arranged in abutting arrangement to define a fluid passage within the slot and between adjacent ones of the plurality of longitudinal segments. The fluid passage extends between the first axial end portion and the second axial end portion of the stator core. The electric motor system includes a fluid coolant system configured to provide a coolant fluid into the cavity for the coolant fluid to flow along the fluid passage between the first axial end portion and the second axial end portion.

[0008] In another embodiment, a method of manufacturing an electric machine is disclosed. The method includes providing a stator core having a first axial end portion and a second axial end portion separated along a longitudinal axis. The stator core has a slot extending between the first axial end portion and the second axial end portion. The method also includes providing a plurality of winding members including a plurality of longitudinal segments. Further, the method includes inserting the plurality of longitudinal segments into the slot to extend between the first axial end portion and the second axial end portion. Each of the plurality of longitudinal segments has a non-circular cross-sectional profile. Inserting the plurality of longitudinal segments includes arranging the plurality of longitudinal segments in abutting arrangement to define a fluid passage within the slot and between adjacent ones of the plurality of longitudinal segments. The fluid passage extends between the first axial end portion and the second axial end portion of the stator core.

[0009] Further, other desirable features and characteristics of the present disclosure will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the background. BRIEF DESCRIPTION OF DRAWINGS

[0010] The present disclosure will be described with respect to the attached drawings, wherein like reference numerals denote like elements, and in which: Figure 1 is a schematic illustration of an electric machine system according to example embodiments of the present disclosure; Figure 2 is an isometric longitudinal sectional view of a stator member of an electric machine system according to example embodiments; Figure 3 is a sectional detail view of the stator member taken along a midline 3-3 according to example embodiments; Figure 2 Figure 4 is a sectional detail view of the stator member taken along a midline 3-3 according to example embodiments; Figure 2 ​a cross-sectional detail view of the stator member shown; Figure 5 is in accordance with an example embodiment Figure 2 a cross-sectional detail view of the stator member shown; Figure 6 is in accordance with an example embodiment Figure 2 a cross-sectional detail view of the stator member shown; and Figure 7 is in accordance with an example embodiment Figure 2 a cross-sectional detail view of the stator member shown. DETAILED DESCRIPTION

[0011] The following detailed description is merely illustrative in nature and is not intended to limit the disclosure or the application and uses of the disclosure. As used herein, the term "exemplary" means "serving as an example, instance, or illustration." Thus, any implementation described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described herein are exemplary implementations provided to enable persons skilled in the art to make or use the disclosure and not to limit the scope of the disclosure. Furthermore, to the extent that any

[0012] Generally, example embodiments disclosed herein include an electric machine system, such as an electric motor system, having features for providing effective cooling for efficient operation of the electric machine.

[0013] For example, a stator member of the electric machine can include a stator core having a plurality of slots (i.e., grooves, passages, etc.) extending between a first axial end and a second axial end of the stator core. Each slot can extend along a respective longitudinal axis, which can be parallel to a rotational axis of a rotating set of the electric machine. Each slot can be arranged (e.g., equidistantly arranged) about the rotational axis. Further, the slots can open into an inner radial surface of the stator core.

[0014] The stator member can further include a plurality of winding members including a plurality of longitudinal segments received in respective ones of the plurality of slots. In at least one slot, there can be a set of longitudinal segments. The longitudinal segments can have a given cross-sectional shape (taken along the longitudinal axis of the slot). Further, the longitudinal segments can be provided in an abutting arrangement (i.e., in layers, oriented, etc.). The shape and arrangement of the winding members can provide a gap between adjacent longitudinal segments. Accordingly, a fluid passage can be defined along the slot and between adjacent ones of the longitudinal segments of the winding.

[0015] The motor system can also include a fluid coolant system that can provide a cooling fluid (refrigerant, coolant, oil, air, other gas, other liquid, etc.) to the motor. The fluid can be provided to the slots to flow between the longitudinal segments of the windings. Thus, the cooling fluid can be provided directly to the windings and through the stator core for efficient cooling.

[0016] Further, the motor can be relatively compact and lightweight. The motor can also provide manufacturing benefits, such as a relatively low number of parts, and ease of assembly, installation, repair, and replacement.

[0017] Figure 1 is a schematic view of a motor system 100 according to example embodiments of the present disclosure. The motor system 100 can have a variety of configurations. In some embodiments, the motor system 100 can be configured as a traction drive system 102, such as included on a vehicle 106. Thus, the traction drive system 102 can be configured to drive one or more wheels 104 of the vehicle 106. More specifically, the wheels 104 can be included at opposite ends of an axle 111, and a chassis 107 can be supported on the wheels 104 by a suspension system (not shown). The vehicle 106 can be an electric car, truck, van, motorcycle, watercraft, or other vehicle. However, it will be appreciated that the motor system 100 can also be configured in other forms without departing from the scope of the present disclosure.

[0018] Generally, the motor system 100 can include a housing 125. The housing 125 can include a motor housing 124 having a cavity 129 therein. The motor system 100 can also include a motor 110 received in the cavity 129 and housed within the motor housing 124.

[0019] In some embodiments, the motor 110 can be an electric motor 112. For example, in some embodiments, the electric motor 112 can be an alternating current, three-phase electric motor. However, it will be appreciated that the motor 110 can also be configured in other forms. In some embodiments, the motor 110 can be configured as an electric generator. Further, the motor 110 can operate as a motor in some modes, and as a generator in additional modes. The motor 110 can include a rotor member 118 and a stator member 119 housed within the cavity 129 of the motor housing 124.

[0020] The rotor member 118 can be supported on the shaft 116, and the shaft 116 can be supported for rotation about the axis 109 (i.e., the rotational axis 109) within the motor housing 124. The stator member 119 of the motor 110 can be fixed within the motor housing 124 and can surround the rotor member 118 and the shaft 116. In embodiments in which the motor 110 is an electric motor 112, the shaft 116 can be referred to as an output shaft 116 of the electric motor 112. In some embodiments, a gear connection member 128 (e.g., a gear, splines on the shaft 116, or other part having gear teeth features) can be operably supported on the shaft 116.

[0021] Further, the motor system 100 can include a transmission 130. The transmission 130 can generally include a gear train 132 housed within a transmission housing 136 of the housing 125. The transmission housing 136 can be attached (e.g., fixed) to the side wall 127 of the motor housing 124.

[0022] The gear train 132 can be of any suitable type. The gear train 132 can operably connect the motor 110 with the axle 111 and can transfer power therebetween. The motor 110 can be coupled to the wheels 104 via the transmission 130. The gear train 132 can be attached to the gear connection member 128 and the axle 111. The transmission housing 136 and the motor housing 124 can be movably supported on the axle 111 by one or more bearings 114 (e.g., bearing sleeves, suspension tubes, etc.) such that the axle 111 can rotate relative thereto.

[0023] During operation, the electric motor 112 can rotatably drive the shaft 116 and the gear connection member 128 supported thereon. This rotational power can be transferred to the gear train 132, which can transfer power to the axle 111 to rotate the wheels 104 and propel the vehicle 106. These operations can be controlled by a control system 133. The control system 133 can control the rotational speed of the motor 112 and / or other functions of the motor 112.

[0024] Further, the motor system 100 can include a fluid coolant system 140. The fluid coolant system 140 can be configured for circulating a fluid, such as a fluid coolant. The fluid can be a liquid, coolant oil, etc.

[0025] The fluid coolant system 140 can be coupled to the stator member 119 as will be discussed. Additionally, the fluid coolant system 140 and the stator member 119 can include features that provide cooling to the stator member 119. This, in turn, can provide cooling to the rotor member 118, bearings, and / or other adjacent areas of the motor 110.

[0026] As Figure 2As shown, the motor housing 124 can be cylindrical and hollow. The motor housing 124 can include an outer radial wall 150, a first axial wall 151, and a second axial wall 152. The outer radial wall 150 can extend in a circumferential direction about the rotational axis 109 and can extend longitudinally between the first axial wall 151 and the second axial wall 152. The first axial wall 151 and the second axial wall 152 can be disc-shaped and can extend transverse to the axis 109. In some embodiments, the outer radial wall 150 and the first axial wall 151 can be integrally connected to form a unitary and monolithic piece, while the second axial wall 152 can be removably attached to the other end of the outer radial wall 150. The outer radial wall 150, the first axial wall 151, and the second axial wall 152 can collectively define a cavity 129. The cavity 129 can be substantially cylindrical and can be centered on (centered about) the axis 109.

[0027] The stator member 119 can include a stator core 154. The stator core 154 can be hollow and cylindrical, including an outer radial surface 156, an inner radial surface 158, a first axial end 160, and a second axial end 162. The stator core 154 can include a plurality of disc-shaped laminations stacked together and arranged along the axis 109 to collectively define the outer radial surface 156 and the inner radial surface 158.

[0028] As shown, the stator core 154 can include a plurality of slots 164 (i.e., grooves, passages, etc.). It will be appreciated that individual laminations of the stator core 154 can individually include notches that collectively define the slots 164 when stacked together. Figure 2 And Figure 3 As shown, the stator core 154 can include a plurality of slots 164 (i.e., grooves, passages, etc.). It will be appreciated that individual laminations of the stator core 154 can individually include notches that collectively define the slots 164 when stacked together. Figure 3 One of the slots 164 is shown in detail and can be representative of the others. As shown, the slot 164 can be generally rectangular. Further, in some embodiments, the slot 164 can be open at the inner radial surface 158. The slot 164 can be defined by two radially extending inner slot surfaces 167, 169 and a recessed radial inner slot surface 168. The slot 164 can extend along a longitudinal axis 165 between the first axial end 160 and the second axial end 162 of the stator core 154. The longitudinal axis 165 can be substantially parallel to the rotational axis 109. The slot 164 can be open at the first axial end 160 and the second axial end 162 of the stator core 154. The plurality of slots 164 can be disposed in a spaced apart manner (e.g., equally spaced apart) about the rotational axis 109.

[0029] The stator component 119 may also include a plurality of windings 170 (i.e., winding components, wiring components, etc.). The windings 170 may be conductive and may include a plurality of elongated segments. The windings 170 may be arranged as a plurality of coils that are wound back and forth between a first axial end 160 and a second axial end 162 of the stator core 154 and between different slots 164.

[0030] Therefore, the winding 170 may include a plurality of longitudinal segments 172 received in slots 164 of the stator core 154 and generally extending along the axis 165 of the respective slots 164. Figure 3 As shown, in one of the slots 164, the longitudinal segment 172 may include a first longitudinal segment 181, a second longitudinal segment 182, a third longitudinal segment 183, a fourth longitudinal segment 184, a fifth longitudinal segment 185, and a sixth longitudinal segment 186. It will be understood that any number of longitudinal segments 172 may exist in the slot 164.

[0031] like Figure 2 As shown, winding 170 may further include a plurality of first end members 188 near a first axial end portion 160 of stator core 154 and a plurality of second end members 189 near a second axial end portion 162. The first end members 188 may be connected to corresponding pairs of longitudinal segments 172 in different slots 164, and the first end members 188 may be disposed on the outside of stator core 154 at the first axial end portion 160. In some embodiments, at least one first end member 188 may extend away from the first axial end portion 160 for electrical connection to control system 133. Furthermore, the second end members 189 may be connected to corresponding pairs of longitudinal segments 172 in different slots 164. The second end members 189 may be disposed on the outside of stator core 154 at the second axial end portion 162. The first end members 188 and the second end members 189 may be electrically connected to each of the longitudinal segments 172 in a known manner for operation of stator assembly 119 and operable connection to control system 133.

[0032] Figure 3 An example cross-sectional profile of the longitudinal segment 172 is shown (cut out orthogonal to the axis 165 of the groove 164 and orthogonal to the axis of rotation 109 of the motor 112). Figure 3 An example arrangement 187 of longitudinal segment 172 within slot 164 is also shown.

[0033] As shown in the figure, longitudinal segments 181-186 may have substantially similar cross-sectional profiles. Longitudinal segments 181-186 may be quadrilaterals, thus having a substantially rectangular cross-sectional profile. At least one side of longitudinal segments 181-186 may be substantially flat. For example, the first longitudinal segment 181 may include an inner radial side 190, an outer radial side 192, a first tangential side 193, and a second tangential side 194. The inner radial side 190 may face inward and radially toward axis 109, and may include a recessed inner groove 191 extending along axis 165 and along a large portion (e.g., the entirety) of the first longitudinal segment 181. The outer radial side 192 may face radially outward from axis 109 and may similarly include an outer groove 195. The inner groove 191 and / or the outer groove 195 may be semi-circular in cross-section. The first tangential side 193 and the second tangential side 194 may be substantially flat. The inner groove 191 and the outer groove 195 can be substantially aligned along the radial axis 197 intersecting the axis 109. Therefore, the cross-sectional profile of the first longitudinal segment 181 can be slightly H-shaped.

[0034] Without departing from the scope of this disclosure, the longitudinal segment 172 can be formed, shaped, and provided in various ways. Figure 3 The cross-sectional profile is shown. For example, the wire can be extruded or drawn through a die to shape the cross-sectional profile of the longitudinal segment 172. Once shaped, multiple windings 170 can be arranged on the stator core 154.

[0035] like Figure 3 As shown, longitudinal segments 181-186 can be arranged in a layered or radially stacked arrangement 187 within the slot 164. Longitudinal segments 181-186 can be adjacent to each other in arrangement 187. Longitudinal segments 181-186 can be aligned along the radial axis 197. The first longitudinal segment 181 can be arranged radially inward, closest to the inner radial surface 158 of the stator core 154. The second longitudinal segment 182 can be layered, stacked, or otherwise abutted against the outer radial side 192 to be arranged radially outside the first longitudinal segment 181. The third longitudinal segment 183 can similarly abut against the second longitudinal segment 182 to be arranged radially outside it. The fourth longitudinal segment 184 can abut against the third longitudinal segment 183 to be arranged radially outside it. The fifth longitudinal segment 185 can abut against the fourth longitudinal segment 184 to be arranged radially outside it. The sixth longitudinal segment 186 can abut against the fifth longitudinal segment 185, thereby being arranged radially outside it.

[0036] The cross-sectional profile of the longitudinal segment 172 may have integrally contained features that define fluid passages between adjacent pairs of longitudinal segments 172. For example, in Figure 3In the illustrated embodiment, inner groove 191 and outer groove 195 define such a passage. More specifically, the inner groove 191 of one longitudinal segment 172 can be aligned with the opposing outer groove 195 of another longitudinal segment 172. Thus, opposing pairs of inner grooves 191 and outer grooves 195 can cooperate to define corresponding internal passages 196. For example, the inner groove 191 of the fifth longitudinal segment 185 and the outer groove 195 of the fourth longitudinal segment 184 can cooperate to define... Figure 3 The internal passage 196 is shown. The internal passage 196 may extend along axis 165 and is substantially parallel to the axis of rotation 109. The internal passage 196 may be continuous and uninterrupted from the first axial end 160 to the second axial end 162 of the stator core 154. Internal passages 196 located between other longitudinal segments 172 may be substantially similar, but arranged at different radial locations between the other longitudinal segments 172.

[0037] Furthermore, the arrangement 187 of the longitudinal section 172 can be supported within and substantially centered in the groove 164. The groove 164 can be formed correspondingly to the arrangement 187 of the longitudinal section 172. Therefore, a substantially uniform gap 175 can exist between the inner groove surfaces 167, 168, and 169 of the longitudinal section 172 and the groove 164. The gap 175 can also be open and continuous in the longitudinal direction between the first axial end 160 and the second axial end 162 of the stator core 154. Therefore, the gap 175 can define at least one additional fluid channel 171 longitudinally passing through the stator core 154 and above the arrangement 187 of the longitudinal section 172. Figure 3 As shown, the additional fluid channel 171 may be defined between the radially extending inner groove surface 167 and the first tangential side 193 of the longitudinal segment 172, between the outer radial side 192 and the radial inner groove surface 168, and between the inner groove surface 169 and the second tangential side 194 of the longitudinal segment 172, thereby surrounding the arrangement 187. The outer groove 195 of the sixth longitudinal segment 186 may be opposite the radial inner groove surface 168 to provide additional cross-sectional area for the channel 171.

[0038] The fluid coolant system 140 can be fluidly connected to the internal passages 196 and channels 171 of the stator component 119 to supply it with fluid coolant. For example... Figure 2 As shown, the motor housing 124 may include a coolant inlet 142 and a coolant outlet 144. The coolant inlet 142 and the coolant outlet 144 may be spaced apart along axis 109. The coolant inlet 142 may extend radially into a first axial wall 151. The coolant outlet 144 may extend radially out from a second axial wall 152. The coolant inlet 142 and the coolant outlet 144 may be arranged on opposite sides of axis 109.

[0039] Inlet 142 may extend into the first axial wall 151 and may be fluidly connected to an annular first cavity 146, which extends about axis 109 and about a first axial end 160 of stator core 154. The second axial wall 152 may include a similar annular second cavity 148, which extends about a second axial end 162 of stator core 154. Outlet 144 may be fluidly connected to the second cavity 148.

[0040] The first cavity 146 and the second cavity 148 are fluidly connected to the groove 164, and therefore to the internal passage 196 and the fluid channel 171. Thus, during operation, fluid supplied by the inlet 142 can flow into the first cavity 146 and flow around, between, and within the longitudinal section 172. This fluid can also flow between the inner groove surfaces 167, 168, and 169 of the arrangement 187 and the stator core 154. This fluid can absorb heat as it flows longitudinally through the groove 164 and can flow into the second cavity 148 before being discharged via the outlet 144.

[0041] Therefore, when the coolant flows longitudinally along the stator member 119, the fluid coolant can flow on, between, and within the arrangement 187 of the longitudinal section 172. Thus, the fluid coolant system 140 can effectively cool the motor 112. Furthermore, the motor system 100 can be compact and lightweight. Additionally, the number of parts can be relatively small, and the motor system 100 can be manufactured with high efficiency.

[0042] See now Figure 4 An additional embodiment of the arrangement 287 of the longitudinal segment 272 within the slot 264 will be discussed. Figure 3 The features corresponding to the embodiments are indicated by the corresponding reference numerals with 100 added.

[0043] As shown in the figure, each of the longitudinal segments 272 can be substantially quadrilateral, wherein the inner radial side 290, the first tangential side 293, and the second tangential side 294 are substantially flat in cross-sectional profile. At least one longitudinal segment 272 may include at least one protrusion, such as a first rib 234 and a second rib 235 protruding from the outer radial side 292. The first rib 234 and the second rib 235 can be rectangular and can project radially outward from the axis of rotation. Therefore, the cross-sectional profile of the longitudinal segment 272 can be symmetrical with respect to the radial axis 297 and asymmetrical with respect to the tangent 215 orthogonal to the radial axis 297. In arrangement 287, the first rib 234 and the second rib 235 of one of the longitudinal segments 272 can abut against the inner radial side 290 of an adjacent longitudinal segment 272. For example, the ribs 234 and 235 of the third longitudinal segment 283 can abut against the inner radial side 290 of the fourth longitudinal segment 284. Thus, the integrally attached ribs 234, 235 can space the inner radial side 290 (in the radially outer direction) of the fourth longitudinal segment 284 from the third longitudinal segment 283. Therefore, an internal channel 296 can be defined in the space between the outer radial side 292 of the third longitudinal segment 283 and the inner radial side 290 of the fourth longitudinal segment 284. Furthermore, the ribs 234, 235 of the sixth longitudinal segment 286 can protrude toward the radially inner groove surface 268, thereby partially defining the additional channel 271. Figure 4 Other features of the embodiments may be related to Figure 3 The embodiments are basically similar, and these features will not be described again.

[0044] See now Figure 5 An additional embodiment of the arrangement 387 of the longitudinal segment 372 within the slot 364 will be discussed. Figure 3 The features corresponding to the embodiments are indicated by the corresponding reference numerals with 200 added.

[0045] As shown, the longitudinal segments 372 may have a wavy or other contoured (with contoured) cross-sectional profile. These longitudinal segments 372 may be asymmetrical with respect to the radial axis 397. For example, the longitudinal segments 372 may be substantially quadrilateral, wherein the first tangential side 393 and the second tangential side 394 are substantially flat in the cross-sectional profile. Furthermore, the inner radial side 390 and the outer radial side 392 may similarly be contoured and wavy with respect to a plane orthogonal to the axis 397. Thus, the inner radial side 390 and the outer radial side 392 may include both a three-dimensional convex curvature 355 and a concave curvature 357 with respect to the radial axis 397. In some embodiments, the thickness 376 (measured between the inner radial side 390 and the outer radial side 392) may be substantially constant. Furthermore, when arranged and stacked along the radial axis 397 in arrangement 387, the orientation of the profile of one longitudinal segment 372 (with respect to the radial axis 397) may be opposite to that of the adjacent longitudinal segments 372. In other words, the longitudinal segment 372 can be rotated (e.g., 180 degrees) about axis 397 relative to one or more adjacent longitudinal segments 372 in the stacked arrangement 387. Therefore, the second longitudinal segment 382 may include a convex curvature 355 on its outer radial side 392 that is radially aligned with a convex curvature 355 on the inner radial side 390 of the third longitudinal segment 383, to define an adjacent region 373 therebetween. Furthermore, the second longitudinal segment 382 may include a concave curvature 357 on its outer radial side 392 that is radially aligned with a concave curvature 357 on the inner radial side 390 of the third longitudinal segment 383. Thus, the aligned concave curvatures 357 can define respective internal passages 396. Additional passages 371 may also be partially defined by the wavy and contoured shape of the longitudinal segments 372.

[0046] See now Figure 6 An additional embodiment of the arrangement 487 of the longitudinal segment 472 within the slot 464 will be discussed. Figure 3 The features corresponding to the embodiments are indicated by the corresponding reference numerals with 300 added.

[0047] As shown, each of the longitudinal segments 472 can be substantially quadrilateral, wherein the inner radial side 490, outer radial side 492, first tangential side 493, and second tangential side 494 are substantially flat in the cross-sectional profile. The inner radial side 490 and outer radial side 492 can be substantially parallel and can be orthogonal to the radial axis 497. The first tangential side 493 and the second tangential side 494 can be non-parallel. Therefore, the cross-sectional profile can be trapezoidal. The cross-sectional profile can also be asymmetrical with respect to the tangent 415. An internal passage 496 between adjacent longitudinal segments 472 can, for example, be defined between the inclined first tangential side 493 and the adjacent outer radial surface 492. Similarly, the internal passage 496 can also be defined between the inclined second tangential side 494 and the adjacent outer radial surface 492. The gap 475 between the arrangement 487 and the groove 464 can also be defined by the inclined first tangential side 493 and the second tangential side 494, thereby defining an additional fluid passage 471.

[0048] See now Figure 7 An additional embodiment of the arrangement 587 of the longitudinal segment 572 within the slot 564 will be discussed. Figure 3 The features corresponding to the embodiments are indicated by the corresponding reference numerals with 400 added.

[0049] As shown, each of the longitudinal segments 572 can have an elliptical (oval) cross-sectional profile. The longitudinal segment 572 can have a major axis 535 and a minor axis 537. The major axis 535 can be larger than the minor axis 537. The minor axis 537 of the longitudinal segment 572 can be aligned along the radial axis 597 of the groove 564, while the major axis 535 can be transverse to the minor axis 537. Therefore, the internal passage 596 between adjacent longitudinal segments 572 can, for example, be defined between the elliptical longitudinal segments 572. The gap 575 between the arrangement 587 and the groove 564 can also be defined by the elliptical cross-sectional profile of the longitudinal segments 572, thereby defining an additional fluid passage 571.

[0050] In this document, relational terms such as "first" and "second" may be used only to distinguish one entity or action from another, without necessarily requiring or implying any actual such relationship or order between these entities or actions. Ordinal numbers such as "first," "second," and "third" simply indicate different individuals among a plurality, without implying any order or sequence unless specifically defined by the language of the claims. The order of any claim text does not imply that process steps must be performed in that order chronologically or logically, unless specifically defined by the language of the claims. Process steps may be interchanged in any order without departing from the scope of this disclosure, provided that such interchange does not contradict the language of the claims and is not logically absurd.

[0051] Furthermore, depending on the context, terms used to describe the relationship between different elements, such as “connection” or “linkage,” do not imply that there must be a direct physical connection between these elements. For example, two elements can be connected to each other physically, electronically, logically, or in any other way through one or more additional elements.

[0052] As used herein, the term "axial" refers to a direction that is generally parallel to or coincides with an axis of rotation, axis of symmetry, or the centerline of one or more components. For example, in a cylinder or disk having a centerline and generally circular ends or opposite faces, the "axial" direction may refer to a direction that is generally parallel to or coincides with the centerline extending between opposite ends or opposite faces. In some cases, the term "axial" may be used with respect to non-cylindrical (or otherwise radially symmetrical) components. For example, for a rectangular housing containing a axis of rotation, the "axial" direction may be considered to be generally parallel to or coincident with the axis of rotation of that axis. Furthermore, as used herein, the term "radial" may refer to a direction or component relationship relative to a line extending outward from a shared centerline, axis, or similar reference, such as in a plane of a cylinder or (circular) disk perpendicular to that centerline or axis. In some cases, components may be considered to be "radially" aligned even if one or two components may not be cylindrical (or otherwise radially symmetrical). Furthermore, the terms “axial” and “radial” (and any of their derivatives) may cover directional relationships that are not precisely aligned with (e.g., tilted towards) the actual axial and radial dimensions, as long as the relationship is primarily in the respective nominal axial or radial direction. As used herein, the term “substantially” means within 5% to account for manufacturing tolerances. Similarly, as used herein, the term “about” means within 5% to account for manufacturing tolerances.

[0053] While at least one exemplary embodiment has been presented in the foregoing detailed description of this disclosure, it should be understood that numerous variations exist. It should also be understood that one or more exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or construction of this disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient roadmap for implementing exemplary embodiments of this disclosure. It should be understood that various changes may be made to the function and arrangement of the elements described in the exemplary embodiments without departing from the scope of this disclosure as set forth in the appended claims.

Claims

1. An electric motor, comprising: A stator core having a first axial end and a second axial end separated along a longitudinal axis, the stator core having a groove extending between the first axial end and the second axial end; A plurality of winding members comprising a plurality of longitudinal segments received in the slot and extending between a first axial end and a second axial end, each of the plurality of longitudinal segments having a non-circular cross-sectional profile, the plurality of longitudinal segments being arranged adjacently to define a fluid passage within the slot and between adjacent longitudinal segments, the fluid passage extending between the first axial end and the second axial end of the stator core.

2. The motor as described in claim 1, characterized in that, The adjacent longitudinal segments include a first longitudinal segment and a second longitudinal segment among the plurality of longitudinal segments, the first longitudinal segment including a first groove, and wherein, in the adjoining arrangement, the first longitudinal segment among the plurality of longitudinal segments abuts against the second longitudinal segment among the plurality of longitudinal segments; The first groove cooperates with the second longitudinal segment of the plurality of longitudinal segments to define the fluid passage.

3. The motor as described in claim 2, characterized in that, The second longitudinal segment of the plurality of longitudinal segments includes a second trench; and The first groove and the second groove cooperate to define the fluid passage.

4. The motor as described in any of the preceding claims, characterized in that, The adjacent longitudinal segments include a first longitudinal segment and a second longitudinal segment among the plurality of longitudinal segments, the first longitudinal segment including a first side having a protrusion extending from the first side, and the protrusion abutting against the second longitudinal segment among the plurality of longitudinal segments in the adjacent arrangement; The first side cooperates with the second longitudinal segment of the plurality of longitudinal segments to define the fluid channel.

5. The motor as described in claim 4, characterized in that, The second longitudinal segment of the plurality of longitudinal segments includes a flat second side; Wherein, the protrusion abuts against the second side; and The first side and the second side cooperate to define the fluid channel.

6. The motor as claimed in any one of the preceding claims, characterized in that, The adjacent longitudinal segments include a first longitudinal segment and a second longitudinal segment among the plurality of longitudinal segments, wherein the first longitudinal segment includes a waveform cross-sectional profile having a concave profile and a convex profile, and the convex profile abuts against the second longitudinal segment among the plurality of longitudinal segments in the adjacent arrangement. The concave profile engages with a second longitudinal segment of the plurality of longitudinal segments to define the fluid channel.

7. The motor as described in claim 6, characterized in that, The first and second longitudinal segments of the plurality of longitudinal segments are stacked along the radial axis; The second longitudinal segment of the plurality of longitudinal segments includes a waveform cross-sectional profile having opposite concave profiles and opposite convex profiles, wherein the concave profiles and the opposite concave profiles are profiled opposite to each other along the radial axis, and the convex profiles and the opposite convex profiles are profiled opposite to each other along the radial axis. Wherein, the convex profile of the first longitudinal segment is adjacent to the opposite convex profile of the second longitudinal segment; and Wherein, the concave profile of the first longitudinal segment is aligned along the radial axis with the opposite concave profile of the second longitudinal segment to define the fluid channel.

8. The motor as described in claim 6, characterized in that, The cross-sectional profile has at least one profiled side and at least one flat side.

9. The motor as claimed in any of the preceding claims, characterized in that, The cross-sectional profile is trapezoidal.

10. The motor as claimed in any of the preceding claims, characterized in that, The cross-sectional profile is elliptical.

11. The motor as claimed in any one of the preceding claims, characterized in that, The slot is defined by the inner slot surface of the stator core; The plurality of longitudinal segments are arranged adjacently within the groove to define another fluid channel between the inner groove surface and the plurality of longitudinal segments, the other fluid channel extending substantially along the longitudinal axis.

12. The motor as claimed in any of the preceding claims, characterized in that, It also includes a motor housing defining a cavity, in which the stator core is received, the motor housing having a fluid inlet and a fluid outlet, the fluid inlet and the fluid outlet being spaced apart along the longitudinal axis, and the fluid inlet and the fluid outlet being in fluid communication with the fluid channel.

13. The motor as claimed in any of the preceding claims, characterized in that, The cross-sectional profile is asymmetrical.

14. An electric motor system, comprising: Housing, the housing defining a motor cavity; An electric motor received in a motor cavity, the electric motor including a stator core having a first axial end and a second axial end separated along a longitudinal axis, the stator core having a slot extending between the first axial end and the second axial end, the electric motor including a plurality of winding members including a plurality of longitudinal segments received in the slot and extending between the first axial end and the second axial end, each of the plurality of longitudinal segments having a non-circular cross-sectional profile, the plurality of longitudinal segments being arranged adjacently to define a fluid passage within the slot and between adjacent longitudinal segments, the fluid passage extending between the first axial end and the second axial end of the stator core; as well as A fluid coolant system configured to provide coolant fluid into the cavity for flow along the fluid passage between the first axial end and the second axial end.

15. The electric motor system as described in claim 14, characterized in that, The housing has a fluid inlet and a fluid outlet, the fluid inlet and the fluid outlet being spaced apart along the longitudinal axis, and the fluid inlet and the fluid outlet being in fluid communication with the fluid channel.

16. The electric motor system as described in claim 14 or 15, characterized in that, The slot is defined by the inner slot surface of the stator core; The plurality of longitudinal segments are arranged in the groove in the adjacent manner to define another fluid channel between the inner groove surface and the plurality of longitudinal segments, the other fluid channel extending substantially along the longitudinal axis.

17. The electric motor system as described in claim 14, 15, or 16, characterized in that, The adjacent longitudinal segments include a first longitudinal segment and a second longitudinal segment among the plurality of longitudinal segments, the first longitudinal segment including a first groove, and wherein, in the adjoining arrangement, the first longitudinal segment among the plurality of longitudinal segments abuts against the second longitudinal segment among the plurality of longitudinal segments; The first groove cooperates with the second longitudinal segment of the plurality of longitudinal segments to define the fluid passage.

18. The electric motor system as described in claim 14, 15, 16, or 17, characterized in that, The adjacent longitudinal segments include a first longitudinal segment and a second longitudinal segment among the plurality of longitudinal segments, the first longitudinal segment including a first side having a protrusion extending from the first side, and the protrusion abutting against the second longitudinal segment among the plurality of longitudinal segments in the adjacent arrangement; The first side cooperates with the second longitudinal segment of the plurality of longitudinal segments to define the fluid channel.

19. The electric motor system as described in claim 14, 15, 16, 17 or 18, characterized in that, The adjacent longitudinal segments include a first longitudinal segment and a second longitudinal segment among the plurality of longitudinal segments, the first longitudinal segment including a first side having a protrusion extending from the first side and including a groove in the first side; The first side cooperates with the second longitudinal segment of the plurality of longitudinal segments to define the fluid channel.

20. A method for manufacturing an electric motor, comprising: A stator core is provided having a first axial end and a second axial end separated along a longitudinal axis, the stator core having a groove extending between the first axial end and the second axial end; A plurality of winding components are provided, the plurality of winding components including a plurality of longitudinal segments; as well as The plurality of longitudinal segments are inserted into the groove to extend between the first axial end and the second axial end, each of the plurality of longitudinal segments having a non-circular cross-sectional profile, and the plurality of longitudinal segments are arranged in an adjacent manner to define a fluid passage within the groove and between adjacent longitudinal segments, the fluid passage extending between the first axial end and the second axial end of the stator core.

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