Method of making a dynamoelectric machine conductor bar and method of making a conductor bar dynamoelectric machine

A method for making a dynamoelectric machine conductor bar, compromising:

• providing a plurality of bundled together spiraling strand conductors having surrounding insulation to define a substantially rectangular shape, with the strand conductors and strand insulation defining an opposing conductor bar end portion having an electrically insulated gap between the strand insulation adjacent the bar end portion;
• and
• applying a fillet as a filler material to fill the gap to electrically shield the conductor bar end portion and to define a greater than 0.080 inch continuous outer radius surface end portion;
• wherein the fillet comprises an electrically non-conducting material with an outer surface that comprises a low conductivity paint having a conductivity in the range of 2,000 to 100,000 ohms per square in its cured state.

A method for making a dynamoelectric machine having a stator with a high voltage winding comprising a plurality of conductor bars extending along slots in the winding, comprising:

• providing a plurality of bundled tog ether spiraling strand conductors having surrounding insulation to define a substantially rectangular shape, with the strand conductors and strand insulation defining an opposing conductor bar end portion having an electrically insulated gap between the strand insulation adjacent the bar end portion;
• and
• applying a fillet as the filler material to fill the gap to electrically shield the conductor bar end portion and to define a a greater than 0.080 inch continuous outer radius surface end portion,
• wherein the fillet comprises an electrically non-conducting material with an outer surface that comprises a low conductivity paint having a conductivity in the range of 2,000 to 100,000 ohms per square in its cured state.