Stator winding for an electrical machine

A method of manufacturing a multi-phase electrical machine, the method comprising the steps of:

• casting in a mould a conductor for a winding of a stator of the multi-phase electrical machine, the conductor being cast having first and second substantially parallel legs and a bridge portion extending, in a direction substantially perpendicular to the legs, between respective first ends of the first and second legs, to electrically connect the first and second legs, the bridge portion being cast so as to comprise:
• a first bridge part extending in a first plane substantially perpendicular to the first and second legs, from a first end of the first leg;
• a second bridge part, extending from a first end of the second leg, in a second plane substantially perpendicular to the first and second legs, to connect the second leg to the first bridge part;
• and a longitudinally extending portion extending longitudinally to the stator and connecting the first bridge part and the second bridge part;
• removing the conductor from the mould;
• and
• inserting the first and second legs of the conductor into slots in a stator core of the multi-phase electrical machine, such that at least a portion of the bridge portion lies in a plane substantially parallel with an end face of the core, the legs of the conductor being cast so as to extend within the first and second slots of the stator core, from the bridge portion located at a first longitudinal end of the stator core, to a second longitudinal end of the stator core.

A stator for a multi-phase electrical machine, comprising:

• a stator core having a substantially annular cross section and having a plurality of slots extending longitudinally in a direction of a rotation axis of the stator, for receiving conductors to form magnetic windings of the stator;
• and
• a substantially circular array of cast conductors, cast conductors of the array comprising:
• a first substantially straight leg and a second substantially straight leg extending substantially parallel to one another within first and second slots of the stator core;
• and
• a bridge portion, comprising:
• a first bridge part extending in a first plane substantially perpendicular to the first and second legs, from a first end of the first leg, to form a part of an electrical connection between the first and second legs;
• a second bridge part, extending from a first end of the second leg, in a second plane substantially perpendicular to the first and second legs, to connect the second leg to the first bridge part;
• and
• a step portion extending longitudinally to the stator and connecting the first bridge part and the second bridge part;
• wherein the first substantially straight leg and the second substantially straight leg extend within the first and second slots of the stator core from the bridge portion at a first longitudinal end of the core, to a second longitudinal end of the stator core.