Methods of insulating lead connections for dynamoelectric machine

Abstract

A connection insulator for a dynamoelectric machine having a magnetic core and at least one winding arranged thereon comprising a plurality of coils of wire conductors with end turns thereof projecting beyond side faces of the core and being subject to pressure forces during compacting and forming and with lead wires extending therefrom. The insulator is formed of a flexible heat-shrinkable electrical insulating material and comprises a tubular portion with an open end adapted to receive an electrical connection joining at least one of the lead wires with another wire and a closed end with an integral flat tab portion extending axially therefrom at a junction with the tubular portion. A substantial part of the tab portion spaced from the junction is adapted to be grippingly engaged by the end turns of one of the coils and a substantial part of the tubular portion spaced from the junction is adapted to be grippingly engaged by the end turns of an adjoining coil. The electrical connection is located within the tubular portion and adjacent the closed end thereof. The parts of the tubular and tab portions not engaged by the end turns of adjoining coils span a space between adjoining coils and are substantially unaffected by pressure forces applied during compacting and forming of the end turns. A stator assembly with lead wire connections insulated by these connection insulators and methods of forming such stator assemblies are also described.