Induction rotor assembly with thin foils

A vehicle motor, comprising:

• a stator;
• and
• an induction rotor assembly configured to rotate due to a rotating magnetic field created by the stator, wherein the induction rotor assembly includes
• a laminated stack including a body having a first end and an opposing second end arranged along a longitudinal axis, the body having an outer circumferential surface extending from the first end to the second end along the longitudinal axis, the outer circumferential surface having a plurality of grooves extending from the first end to the second end;
• a plurality of foils, wherein each one of the plurality of foils is disposed within one of the grooves;
• a plurality of conductor bars, wherein each of the plurality of conductor bars is disposed within each of the grooves, wherein each one of the plurality of foils is disposed between each one of the plurality of conductor bars and each one of the grooves, wherein each of the plurality of conductor bars includes a first conductor end extending axially beyond the first end of the laminated stack and a second conductor end extending axially beyond the second end of the laminated stack, and wherein multiple foil layers are disposed between each groove and each conductor bar;
• a first end ring mating with a surface of each first conductor end to interlock each of the plurality of conductor bars to the first end ring;
• and
• a second end ring mating with a surface of each second conductor end to interlock each of the plurality of conductor bars to the second end ring, and wherein the plurality of conductor bars extends between the first end ring and the second end ring.

A method of manufacturing an induction rotor assembly, comprising:

• laminating a plurality of steel sheets to form a laminated stack having a first end and an opposing second end axially spaced along a longitudinal axis, wherein a plurality of grooves are disposed on an outer circumferential surface of the laminated stack and extend from the first end to the second end;
• placing a plurality of foils in the plurality of grooves;
• forming a conductor bar in each of the grooves such that each one of the plurality of foils is disposed between each conductor bar and the laminated stack, wherein a first conductor end extends axially beyond the first end of the laminated stack, and wherein multiple foil layers are disposed between each groove and each conductor bar;
• and
• casting a first end ring in place around each first conductor end of each of the conductor bars and a second end ring in place around each second conductor end of each of the conductor bars to at least partially surround and electrically connect the first conductor end and the second conductor end of each of the plurality of conductor bars.