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Borgwarner Inc.

David Lee Durant

Kirk E Neet

Ryan J Jones

Timothy Beatty

A stator for an electric machine comprises a cylindrical core defining an inner cylindrical surface and an outer cylindrical surface with a plurality of slots formed between the inner cylindrical surface and the outer cylindrical surface. Windings are positioned on the cylindrical core. The leads of the windings include a plurality of inner leads associated with conductors in an inner layer of the slots and a plurality of outer leads associated with conductors in an outer layer of the slots. A bus bar assembly includes a plurality of inner bus bars and a plurality of outer bus bars, the plurality of inner bus bars connected to the plurality of inner leads, and the plurality of outer bus bars connected to the plurality of outer leads. The plurality of outer bus bars are positioned radially outward from the end turns of the windings and radially inward from the outer cylindrical surface.

Stator with outer diameter bus bar connection

A laminated sheet allows circuit boards to be fabricated without any special equipment. The laminated sheet can be printed using an ordinary laser printer on a personal computer. The sheet has a conductive layer, such as copper, attached to a nonconductive flexible substrate, such as Kapton. The outer surface of the copper is coated with an ink which provides a receiving surface for toner when the laminated sheet is fed through a printer. The other side of the flexible substrate is attached to a removable layer of paper which provides support for the laminated sheet during the printing process. The paper is removed after printing and the adhesive which held the paper is used to attach the flexible substrate to a rigid substrate. Alcohol is used to remove the ink and expose the copper for etching. The alcohol does not remove the toner which acts as a mask during the etching process. The toner is removed after board fabrication. An alignment procedure allows circuit land patterns to be placed on both sides of a circuit board.

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Anderson, IN, United States of America

David Lee Durant