Liquid cooled stator for high efficiency machine

A rotary electric machine comprising:

• a stator having a circumferentially spaced series of axially extending teeth defining a similar series of circumferentially spaced winding slots therebetween, said teeth being releasably connected to the stator;
• a plurality of stator windings at least partially disposed in each winding slot, the windings being electrically connected to form a plurality of phases, at least one stator winding comprising rectangular wire formed in multiple turns with each turn having a width extending in a radial direction of the stator and a thickness greater than the width extending circumferentially;
• structure defining an even number of elongated coolant passageways disposed in at least one winding slot circumferentially between two windings in the winding slot with the width of the rectangular wire in the slot being adjacent the structure, fluid flowing in one direction for half of the coolant passageways and in the opposite direction for the other half of the coolant passageways;
• and
• a compressible insulating layer extending between the structure and the windings in each slot and having an interface with only a portion of the periphery of each winding in the slot.

A rotary electric machine comprising:

• a stator having a circumferentially spaced series of axially extending teeth defining a similar series of circumferentially spaced winding slots therebetween, said teeth being releasably connected to the stator;
• a plurality of stator windings at least partially disposed in each winding slot, said windings being electrically connected to form a plurality of phases with at least a portion of the winding slots having only one phase of windings therein, at least one of the stator windings comprising rectangular wire formed in multiple turns with each turn having a width extending in a radial direction of the stator and a thickness greater than the width extending circumferentially;
• structure defining a plurality of elongated coolant passageways disposed in each winding slot;
• a silicon rubber, compressible insulating layer wrapped around and engaging each structure;
• and
• a resin extending around the insulating layers and formed from a material different from the material of the insulating layers, the space circumferentially between the structure and the windings being free of resin within the winding slot.

A rotary electric machine comprising:

• a stator having a circumferentially spaced series of axially extending teeth defining a similar series of circumferentially spaced winding slots therebetween, said teeth being releasably connected to the stator;
• a plurality of stator windings at least partially disposed in each winding slot, said windings being electrically connected to form a plurality of phases wherein one or more slots contain the same magnitude of peak current for each phase;
• structure defining a plurality of elongated coolant passageways disposed in each winding slot and external to the windings, wherein coolant passageways in winding slots in one of the plurality of phases are not fluidly connected in series with coolant passageways in winding slots in another of the plurality of phases;
• and
• at least some of said coolant passageways being formed by a plurality of adjacent structures fluidly connected together at only one end of the machine.