Hollow copper electrical conductors
AssigneeGM Global Technology Operations LLC
InventorsSayed Youssef Sayed Nagy, Anil K. Sachdev, Anthony Michael Coppola, Jian Yao, Chengwu Duan
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Abstract
A process for making a hollow electrical coil for an electric motor includes forming a sacrificial insert material into a coil shaped insert. The coil shaped insert is placed into a copper plating bath and a copper plated coil shaped member is removed from the copper plating bath. The sacrificial material is removed from within the copper plated coil shaped member to create a hollow passage through a hollow copper coil shaped member. An exterior of the hollow copper coil shaped member is coated with an insulating adhesive material and the copper coil shaped member is compressed until the insulating adhesive material is set.
Claims17
A process for making a coil assembly having hollow electrical coils for an electric motor, comprising:
- forming a plurality of hollow electrical coils by;
- forming a sacrificial insert material into a coil shaped insert;
- placing the coil shaped insert into a copper plating bath;
- removing a copper plated coil shaped member from the copper plating bath;
- removing the sacrificial insert material from within the copper plated coil shaped member to create a hollow passage through a hollow copper coil shaped member;
- coating an exterior of the hollow copper plated coil shaped member with an insulating adhesive material;
- and
- compressing the copper coil shaped member until the insulating adhesive material is set;
- forming the coil assembly by connecting an inlet coolant ring to a first end to the hollow electrical coils at a first end of the coil assembly and connecting an outlet coolant ring to a second end of the hollow electrical coils at a second end of the coil assembly;
- and
- electrically connecting a plurality of phase wirings to the plurality of hollow electrical coils adjacent to one of the inlet coolant ring and the outlet coolant ring.
A process for making a coil assembly having hollow electrical coils for an electric motor, comprising:
- forming a plurality of hollow electrical coils by;
- forming an insert material into a coil shaped insert with a hollow passage therethrough;
- placing the coil shaped insert into a copper plating bath;
- removing a copper plated coil shaped member from the copper plating bath;
- coating an exterior of the hollow copper plated coil plated shaped member with an insulating adhesive material;
- and
- compressing the copper plated coil shaped member until the insulating adhesive material is set;
- forming the coil assembly by connecting an inlet coolant ring to a first end to the hollow electrical coils at a first end of the coil assembly and connecting an outlet coolant ring to a second end of the hollow electrical coils at a second end of the coil assembly;
- and
- electrically connecting a plurality of phase wirings to the plurality of hollow electrical coils adjacent to one of the inlet coolant ring and the outlet coolant ring.
A coil assembly for an electric motor, comprising
- a plurality of conductive coils arranged in an annular ring and each having a hollow passage therethrough, the plurality of conductive coils having a first end and a second end;
- a coolant inlet ring disposed at a first longitudinal end of the coil assembly and connected to the first end of each of the plurality of conductive coils;
- a coolant outlet ring disposed at a second longitudinal end of the coil assembly and connected to the second end of each of the plurality of conductive coils;
- and
- a plurality of phase wirings electrically connected to the plurality of electrical coils adjacent to one of the coolant inlet ring and the coolant outlet ring.
Dependencies are inferred from the claim text.