Terminal assembly for encapsulated stator

A method of assembling a terminal assembly for a stator, the method comprising:

• connecting a magnet wire to a first arm of an elbow terminal;
• disposing an insulating tube about a second arm of the elbow terminal, the second arm disposed at a 90 degree angle relative to the first arm;
• securing the insulating tube in encapsulation tooling;
• pouring encapsulant material through the encapsulation tooling into the stator.

A stator for an electric submersible pump motor, the stator comprising:

• a housing;
• a plurality of laminations forming a lamination stack within the housing;
• slots extending axially through the lamination stack;
• windings extending axially through the slots;
• an end turn area at a top end of the lamination stack in which the windings extend generally circumferentially;
• encapsulation material surrounding the windings in the end turn area;
• a plurality of lead wires coupled to the windings and extending upward from the end turn area, each lead wire of the plurality of lead wires comprising:
• a solid copper conductor;
• and
• insulation extruded about the conductor, the insulation comprising a structural dielectric material;
• and
• a stator terminal assembly coupling each lead wire of the plurality of lead wires to one or more magnet wires of the windings, the stator terminal assembly comprising:
• an elbow terminal comprising a first arm and a second arm disposed at 90 degrees relative to the first arm, the first arm configured to be connected to the lead wire and the second arm configured to be connected to the one or more magnet wires;
• and
• an insulating tube, wherein the first arm of the elbow terminal extends within the insulating tube and the second arm of the elbow terminal protrudes from the insulating tube.