Electric machine module cooling system and method

An electric machine module comprising:

• a housing including a first end cap and a second end cap, at least one of the first end cap and the second end cap comprising a plurality of recesses including at least a first recess, a second recess, and a third recess;
• and
• an electric machine operatively coupled to the first end cap and the second end cap, the electric machine including a stator assembly including stator end turns, the stator assembly further comprising
• a first axial end and a second axial end,
• at least one first coolant member disposed through at least a portion of the stator assembly and extending from at least the first axial end to the second axial end, and the at least one first coolant member including a curved region and being in fluid communication with the first recess and the second recess, and
• at least one second coolant member disposed through at least a portion of the stator assembly and extending from at least the first axial end to the second axial end, and the at least one second coolant member including a curved region and being in fluid communication with the second recess and the third recess, wherein the at least one first coolant member and the at least one second coolant member comprise a polymer and are configured and arranged to expand into engagement with the stator assembly.

A method of assembling an electric machine module, the method comprising:

• providing a first end cap and a second end cap;
• providing an electric machine including a stator core comprising a first axial end and a second axial end;
• positioning a plurality of stator channels through at least a portion of the stator core so that at least some of the plurality of stator channels extend from the first axial end to the second axial end;
• extruding a plurality of coolant members so that the plurality of coolant members each comprise a curved region, the plurality of coolant members comprising a polymer;
• positioning the plurality of coolant members within the plurality of stator channels so that portions of the plurality of coolant members extend from the first axial end and the second axial end;
• coupling a retaining member to a portion of at least one of the plurality of coolant members;
• introducing a pressurized fluid from one or more nozzles into at least one of the plurality of coolant members to engage the coolant members with the stator channels;
• and
• coupling the first end cap to the first axial end of the stator core and the second end cap to the second axial end of the stator core.