公开(公告)号：US10132270B2

公开(公告)日：2018-11-20

申请号：US15225066

申请日：2016-08-01

Applicant: GM Global Technology Operations LLC

Inventor： Anthony M. Coppola ,  Hamid G. Kia ,  Paul M. Najt ,  Russell P. Durrett ,  Michael A. Potter

IPC: F02P3/02 ,  F02F7/00 ,  F02F1/00 ,  F02F1/16 ,  F02F1/40 ,  F02F1/10

Abstract: Vehicle assemblies, such as engine assemblies, including an integrated cylinder head and plurality of liners as well as a polymeric composite housing are provided. Methods of making such vehicle assemblies are also provided.

公开(公告)号：US20180031027A1

公开(公告)日：2018-02-01

申请号：US15225080

申请日：2016-08-01

Applicant: GM Global Technology Operations LLC

Inventor： Anthony M. Coppola ,  Hamid G. Kia ,  Paul M. Najt ,  Russell P. Durrett ,  Michael A. Potter

IPC: F16C3/08 ,  B21K1/08 ,  F16C3/20

CPC classification number: F16C3/08 ,  B21K1/08 ,  F16C3/023 ,  F16C3/10 ,  F16C3/20 ,  F16C2208/02 ,  F16C2360/22

Abstract: Crankshaft assemblies for vehicle assemblies, such as engine assemblies, and methods of manufacturing crankshaft assemblies are provided. The crankshaft assembly includes a first crankpin disposed between a first pair of webs and at least a first main bearing journal connected to the first pair of webs, wherein at least one of the first crankpin, the first pair of webs or the first main bearing journal is a polymeric composite including a polymer and a plurality of reinforcing fibers.

公开(公告)号：US20180030923A1

公开(公告)日：2018-02-01

申请号：US15225066

申请日：2016-08-01

Applicant: GM Global Technology Operations LLC

Inventor： Anthony M. Coppola ,  Hamid G. Kia ,  Paul M. Najt ,  Russell P. Durrett ,  Michael A. Potter

IPC: F02F7/00 ,  F02F1/00 ,  F02F1/16 ,  F02F1/40

CPC classification number: F02F7/0085 ,  F02F1/002 ,  F02F1/004 ,  F02F1/10 ,  F02F1/102 ,  F02F1/16 ,  F02F1/40 ,  F02F7/0095 ,  F02P3/02 ,  F05C2225/00 ,  F05C2251/048 ,  F05C2253/16

Abstract: Vehicle assemblies, such as engine assemblies, including an integrated cylinder head and plurality of liners as well as a polymeric composite housing are provided. Methods of making such vehicle assemblies are also provided.

公开(公告)号：US20240405346A1

公开(公告)日：2024-12-05

申请号：US18326162

申请日：2023-05-31

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Ryan P. Hickey ,  Mohammad Kirmani ,  Anthony M. Coppola ,  Evan D. Griffith ,  Daniel M. Wang ,  Kris Killen

IPC: H01M50/289 ,  H01M10/658 ,  H01M50/209 ,  H01M50/383

Abstract: A method for constructing a cell support assembly with thermal runaway mitigation for a multi-cell rechargeable energy storage system (RESS) include forming a cell holder configured to support the RESS battery cells. The cell holder has a holder body defining a plurality of apertures arranged in rows, such that each aperture is configured to align and be in fluid communication with a cell vent of one of the RESS battery cells. Individual embodiments of the method also include various techniques of arranging a plurality of thermal-barrier strips and potting elements to align with apertures of the cell holder body and adhering the thermal-barrier strips to the potting elements and to the cell holder. The resultant cell support assembly operates to channel thermal runaway energy away from the affected battery cell(s) and out of the RESS enclosure without triggering thermal runaway in adjacent cells.

公开(公告)号：US11817750B2

公开(公告)日：2023-11-14

申请号：US17149152

申请日：2021-01-14

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Ming Liu ,  Anthony M. Coppola ,  Muhammad H. Alvi

IPC: H02K11/33 ,  H01L25/07 ,  H01L23/31 ,  H01L23/34 ,  H01L23/373 ,  H01L23/50 ,  H02K7/00 ,  H02K11/00 ,  B60L50/60 ,  H01L23/473

CPC classification number: H02K11/33 ,  B60L50/60 ,  H01L23/3107 ,  H01L23/34 ,  H01L23/3735 ,  H01L23/473 ,  H01L23/50 ,  H01L25/072 ,  H02K7/006 ,  H02K11/0094 ,  B60L2210/40 ,  B60L2220/10

Abstract: A planar power module includes a second substrate arranged parallel to a first substrate, with the substrates respectively having a dielectric layer interposed between two conductive layers, such that one of the conductive layers of each substrate together forms parallel external conductive surfaces of the power module. The power module includes direct current (DC) bus bars, alternating current (AC) bus bars, and semiconductor switching dies arranged between the substrates. The dies are electrically connected to the bus bars, with each respective die electrically connected to a conductive layers of the first or second substrates. A polymer molding material partially surrounds the substrates and the switching dies. An electric powertrain system includes an electric machine, a propulsion battery pack, and a traction power inverter module (TPIM) having the power module. The power module is a three-phase full-bridge inverter circuit. An electric powertrain and motor vehicle use the power module.

公开(公告)号：US11757321B2

公开(公告)日：2023-09-12

申请号：US17405480

申请日：2021-08-18

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Alireza Fatemi ,  Anthony M. Coppola ,  Farzad Samie ,  Thomas W. Nehl

IPC: H02K3/24 ,  H02K3/28 ,  H02K3/30 ,  H02K1/16 ,  H02K3/12 ,  H02K1/20 ,  H02K3/34

CPC classification number: H02K3/24 ,  H02K1/165 ,  H02K1/20 ,  H02K3/12 ,  H02K3/28 ,  H02K3/30 ,  H02K3/345

Abstract: A stator assembly for an electric machine includes stator teeth connected to a stator yoke to form a stator core. Adjacent teeth define a stator slot. Stator windings are disposed within the slot. A molding material fills the slot around the windings, providing a desired thermoelectrical performance level at different slot regions, including electrical insulation, thermal conductivity, and/or electrostatic shielding levels. A method insulates the stator assembly by inserting a molding tool(s) into the slot to define a void volume, filling the void volume with the dielectric molding material, and curing the dielectric molding material to form a slot liner layer adjacent to the tooth walls. A slot opening between adjacent teeth is filled with an electrically-conductive resin to form an electrostatic shielding layer. An electrical system includes an AC voltage bus connected to a power inverter module and to the electric machine having the above-described stator assembly.

公开(公告)号：US11689074B2

公开(公告)日：2023-06-27

申请号：US17084181

申请日：2020-10-29

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Anthony M. Coppola ,  Kestutis A. Sonta ,  Alireza Fatemi ,  Gayatri V. Dadheech ,  Yew Sum Leong ,  Xiaosong Huang

IPC: H02K1/28 ,  B60K1/00 ,  H02K1/27 ,  H02K1/32 ,  H02K15/03 ,  H02K21/14 ,  H02K1/276

CPC classification number: H02K1/28 ,  B60K1/00 ,  H02K1/276 ,  H02K1/32 ,  H02K15/03 ,  H02K21/14 ,  B60K2001/006

Abstract: An adhesive-reinforced rotor for a rotary electric machine includes rotor lamination layers (“rotor lams”) having axial inner surfaces collectively defining rotor openings through the rotor lams. The rotor also includes reinforcement blocks disposed within a respective one of the rotor openings. A polymer primer/adhesive layer of the rotor having a bond line thickness of less than 1 mm is disposed between the one or more reinforcement blocks and the axial inner surfaces of the rotor lams. The reinforcement blocks and the primer/adhesive layer each have a tensile strength of at least 50 MPa. A modulus of elasticity of the reinforcement blocks is at least three times greater than that of the materials of the polymer primer/adhesive layer. A method of constructing an adhesive-reinforced rotor is also described herein.

公开(公告)号：US11667091B2

公开(公告)日：2023-06-06

申请号：US16701693

申请日：2019-12-03

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Anthony M. Coppola ,  Nicole Ellison

IPC: B29C70/66 ,  B29C70/02

CPC classification number: B29C70/66 ,  B29C70/025

Abstract: Methods for forming vascular components include providing a composite sacrificial body comprising a first sacrificial material having an outer surface and a second sacrificial material applied to at least a portion of the outer surface, molding a solid substrate around the composite sacrificial body, removing the first sacrificial material by deflagration such that at least a portion of the second sacrificial material remains in the same orientation relative to the substrate as originally molded, and subsequently removing the second sacrificial material by a non-deflagration process to form a vascular component. The second sacrificial material can include a phase change material, a syntactic foam including hollow beads bound together with a polymeric binder or a sintered aggregation of hollow beads, a polymeric foam, a water-soluble resin, or an aerogel. The non-deflagration process can include mechanical pulverization, contacting the second sacrificial material with a solvent or chemical etching agent.

公开(公告)号：US11575299B2

公开(公告)日：2023-02-07

申请号：US16736203

申请日：2020-01-07

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Derek F. Lahr ,  Alireza Fatemi ,  Anthony M. Coppola ,  Sean R. Wagner

IPC: H02K15/03 ,  H02K1/27 ,  H02K15/12 ,  H02K21/14 ,  H02K7/00 ,  H02K1/276 ,  B60K6/26

Abstract: A method for constructing a rotor assembly for use with a rotary electric machine includes forming annular rotor laminations from metal blanks. Each lamination has a radial axis and an outer diameter surface. Multiple magnet web regions are defined in proximity to the outer diameter surface. Each web regions includes asymmetrical openings defined by a radially-extending strut and arcuate peripheral bridges. The method includes coaxially stacking the laminations into a rotor stack, including positioning every other lamination a predetermined angular distance with to unmask the bridges and/or struts and mask remaining surface area of the laminations. The rotor stack is subjected to a heat-treating process to harden only the unmasked bridges and/or struts. The method includes connecting a rotor shaft to the stack to construct the rotor assembly, with the web regions corresponding to a respective rotor magnetic pole.

公开(公告)号：US11338512B2

公开(公告)日：2022-05-24

申请号：US16701528

申请日：2019-12-03

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Anthony M. Coppola ,  Nicole Ellison ,  Hugh MacDowell

IPC: B29C59/08 ,  B29D22/00 ,  B29C64/30 ,  B33Y70/00 ,  B33Y40/20 ,  B29K105/00 ,  B29L31/18

Abstract: Methods for forming channels within a substrate include molding a sacrificial component directly into the substrate and igniting the sacrificial component to deflagrate of the sacrificial component and form a channel in the substrate. The sacrificial component can include oxidizing agents such as chlorates, perchlorates, nitrates, dichromates, nitramides, and/or sulfates imbedded in a polymeric matrix, and the oxidizing agents can be 30 wt. % to 80 wt. % of the sacrificial component. The sacrificial component can further include one or more of unoxidized metal powder fuels, flammable gas-filled polymeric bubbles, one or more metallocenes and/or one or more metal oxide particles, one or more polymers with nitroester, nitro, azido, and/or nitramine functional groups, one or more burn rate suppressants such as oxamide, ammonium sulphate, calcium carbonate, calcium phosphate, and ammonium chloride, and non-combustible hollow bubbles and/or inert particles. The polymeric matrix can have a limiting oxygen index of less than about 30.