Skin effect enhanced high conductive composite stator winding bundles in e-motors

Patent metadata

Field	Value
Publication number	US-12549047-B2
Application number	US-202318506523-A
Country	US
Kind code	B2
Filing date	Nov 10, 2023
Priority date	Nov 10, 2023
Publication date	Feb 10, 2026
Grant date	Feb 10, 2026

Abstract

A composite wire bundle for a stator winding, a stator including a composite wire bundle, and a method of forming a composite wire bundle. The composite wire bundle includes a plurality of copper wires, wherein each of the plurality of copper wires include a first surface. The composite wire bundle also includes a copper-graphene multilayer composite applied to the first surface of each of the plurality of copper wires, wherein the copper-graphene multilayer composite includes a second surface. Further, the composite wire bundle includes a fluoropolymer matrix formed around the second surfaces and a jacket encapsulating the fluoropolymer matrix.

First claim

What is claimed is:

1 . A composite wire bundle for a stator winding, comprising:
a plurality of copper wires, wherein each of the plurality of copper wires include a first surface; a copper-graphene multilayer composite applied to the first surface of each of the plurality of copper wires, wherein the copper-graphene multilayer composite includes a second surface and copper included in the copper-graphene multilayer composite is oxidized at the second surfaces; a fluoropolymer matrix formed around the second surfaces; and a jacket encapsulating the fluoropolymer matrix.

2 . The composite wire bundle of claim 1 , wherein each of the plurality of copper wires exhibit a diameter in the range of 0.3 millimeters to 10 millimeters.

3 . The composite wire bundle of claim 1 , wherein the oxidized copper in the second surface exhibits a thickness in the range of 5 micrometers to 15 micrometers.

4 . The composite wire bundle of claim 1 , wherein the copper-graphene multilayer composite exhibits an electrical conductivity in the range of 105% to 400% of the International Annealed Copper Standard (IACS).

5 . The composite wire bundle of claim 1 , wherein the copper-graphene multilayer composite exhibits a thickness in the range of 10 nanometers to 500 micrometers.

6 . The composite wire bundle of claim 1 , wherein the copper-graphene multilayer composite includes a plurality of alternating layers of graphene and copper.

7 . The composite wire bundle of claim 1 , wherein the copper-graphene multilayer composite includes particles of graphene dispersed between a plurality of coated copper layers.

8 . The composite wire bundle of claim 1 , wherein the fluoropolymer matrix includes polytetrafluoroethylene.

9 . The composite wire bundle of claim 1 , wherein the jacket includes a polymer.

10 . The composite wire bundle of claim 9 , wherein the polymer includes at least one of the following polymers: polyetherimide (PEI), polyether ether ketone (PEEK), polyimide (PI), polyamide imide (PAI), and an epoxy.

11 . The composite wire bundle of claim 9 , wherein the jacket includes multiple polymer layers.

12 . The composite wire bundle of claim 1 , wherein the fluoropolymer matrix includes polytetrafluoroethylene, and the jacket includes a polymer.

13 . The composite wire bundle of claim 1 , wherein the composite wire bundle is wrapped around a plurality of teeth and held in a plurality of channels defined between the plurality of teeth in a stator core.

14 . The composite wire bundle of claim 13 , wherein the composite wire bundle is connected to a busbar.

15 . The composite wire bundle of claim 14 , wherein the busbar is connected to an inverter.

16 . A stator including a composite wire bundle for a vehicle, comprising:
a stator core including a plurality of channels defined by a plurality of teeth; and the composite wire bundle received in the plurality of channels, the composite wire bundle including a plurality of copper wires, wherein each of the plurality of copper wires includes a first surface, a copper-graphene multilayer composite applied to the first surface of each of the plurality of copper wires, wherein the copper-graphene multilayer composite includes a second surface, and copper at the second surface is oxidized, a fluoropolymer matrix formed around the oxidized copper surfaces, and a jacket encapsulating the plurality the fluoropolymer matrix.

17 . A method of forming composite wire bundles for a stator, comprising:
oxidizing copper included in a first surface of a copper-graphene multilayer composite formed on each of a plurality of copper wires; applying a fluoropolymer on the first surface of the copper-graphene multilayer composite formed on each of the plurality of copper wires, wherein the copper included in the first surface of the copper-graphene multilayer composite is oxidized before applying the fluoropolymer; curing the fluoropolymer; consolidating the plurality of copper wires; forming a fluoropolymer matrix with the applied fluoropolymer, wherein the fluoropolymer matrix surrounds the first surfaces; and forming a jacket around the fluoropolymer matrix.

18 . The method of claim 17 , further comprising annealing the copper wires upon curing the fluoropolymer.

19 . The method of claim 17 , wherein the fluoropolymer is applied as a fluoropolymer coating on each wire, wherein the fluoropolymer coating exhibits a thickness in the range of 0.1 micrometers to 500 micrometers.

20 . The method of claim 17 , wherein the plurality of copper wires are consolidated by passing the plurality of copper wires together through a heated die.

Assignees

• Gm Global Tech Operations Llc

Inventors

• Liu Yi
• Li Huaxin
• Agapiou John S
• Wang Qigui
• Sonta Kestutis A

Classifications

• H01R4/04

  using electrically conductive adhesives · CPC title

• H01B1/026

  Alloys based on copper · CPC title

• H01B7/0018

  Strip or foil conductors (H01B7/08 takes precedence) · CPC title

• H01B7/208

  composed of composite laminated metals · CPC title

• H02K15/122

  of windings · CPC title