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公开(公告)号：US12132010B2
公开(公告)日：2024-10-29
申请号：US17225508
申请日：2021-04-08
Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
Inventor： Anthony M. Coppola , Seongchan Pack , Ming Liu
IPC: H01L23/00 , B60K1/04 , H01L21/56 , H01L23/473 , H01L23/552 , H02M7/00
CPC classification number: H01L23/564 , B60K1/04 , H01L23/473 , H01L23/552 , H02M7/003
Abstract: Presented are metal-coated, polymer-encapsulated power semiconductor modules, methods for making/using such power modules, and vehicles with traction power inverters containing such power modules. A power electronics assembly includes one or more power semiconductor modules packaged inside an assembly housing. Each power module includes a substrate, a semiconductor device mounted on the substrate, a polymeric encapsulant encasing therein the substrate and semiconductor device, and an electrical lead connected to the semiconductor device and projecting from the polymeric encapsulant. A metallic or ceramic coating is applied to select sections of the polymeric encapsulant's exposed exterior surface. The metallic/ceramic coating may be a single metallic layer that covers substantially all of the exposed surface area of the polymeric encapsulant's exterior surface. An optional hydrophobic polymer layer, passivated layer, and/or oxidized layer may cover the exterior surface of this metallic layer. Alternatively, another metallic layer or intercalated lamellar microstructures may cover the metallic layer.
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52.发明授权公开(公告)号：US11710993B2
公开(公告)日：2023-07-25
申请号：US17082555
申请日：2020-10-28
Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
Inventor： Anthony M. Coppola , Alireza Fatemi , Yew Sum Leong , Alan G. Holmes
Abstract: An electric machine includes a stator with stator slots securing therein electrically conductive windings. A rotor is rotatably mounted adjacent the stator and includes a stack of rotor laminates. Each laminate includes circumferentially spaced poles, each of which includes a magnet slot spaced from an insert slot. These laminate magnet slots cooperatively define the rotor's magnet slots. Likewise, the laminates' insert slots cooperatively define the rotor's insert slots. Magnets are mounted inside the rotor's magnet slots, and non-magnetic inserts are mounted inside the rotor's insert slots. One or more poles of each laminate includes a structural web that extends radially through the magnet and insert slots of that pole. Multiple poles of each rotor laminate lack a radially extending structural web. Each rotor laminate is rotated with respect to a neighboring rotor laminate such that each pole with a structural web axially aligns with a pole without a structural web.
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公开(公告)号：US11491749B2
公开(公告)日：2022-11-08
申请号：US16701640
申请日：2019-12-03
Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
Inventor： Anthony M. Coppola
Abstract: Methods for forming composite components with sealed bi-material interfaces include applying a sacrificial material to a surface of a substrate, over-molding the substrate and the sacrificial material with an over-molding material such that the over-molding material covers at least a portion of the sacrificial material and at least one surface of the substrate, removing the sacrificial material by deflagration to form a composite component with a channel between the substrate and the over-molding material, introducing an uncured sealant into the channel, and curing the sealant to form a sealed composite component. The method can further include removing a portion of the sealant prior to the sealant fully curing. The sealed composite component can include a passage, encircled by the channel, extending between the substrate and the over-molding material. The substrate can be a metal, a polymer, a polymer composite, a ceramic, or a continuous fiber composite material.
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公开(公告)号：US20220328427A1
公开(公告)日：2022-10-13
申请号：US17225508
申请日：2021-04-08
Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
Inventor： Anthony M. Coppola , Seongchan Pack , Ming Liu
IPC: H01L23/00 , B60K1/04 , H01L23/552 , H01L23/473 , H02M7/00 , H01L21/56
Abstract: Presented are metal-coated, polymer-encapsulated power semiconductor modules, methods for making/using such power modules, and vehicles with traction power inverters containing such power modules. A power electronics assembly includes one or more power semiconductor modules packaged inside an assembly housing. Each power module includes a substrate, a semiconductor device mounted on the substrate, a polymeric encapsulant encasing therein the substrate and semiconductor device, and an electrical lead connected to the semiconductor device and projecting from the polymeric encapsulant. A metallic or ceramic coating is applied to select sections of the polymeric encapsulant's exposed exterior surface. The metallic/ceramic coating may be a single metallic layer that covers substantially all of the exposed surface area of the polymeric encapsulant's exterior surface. An optional hydrophobic polymer layer, passivated layer, and/or oxidized layer may cover the exterior surface of this metallic layer. Alternatively, another metallic layer or intercalated lamellar microstructures may cover the metallic layer.
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55.发明申请公开(公告)号：US20220131431A1
公开(公告)日：2022-04-28
申请号：US17082555
申请日：2020-10-28
Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
Inventor： Anthony M. Coppola , Alireza Fatemi , Yew Sum Leong , Alan G. Holmes
Abstract: An electric machine includes a stator with stator slots securing therein electrically conductive windings. A rotor is rotatably mounted adjacent the stator and includes a stack of rotor laminates. Each laminate includes circumferentially spaced poles, each of which includes a magnet slot spaced from an insert slot. These laminate magnet slots cooperatively define the rotor's magnet slots. Likewise, the laminates' insert slots cooperatively define the rotor's insert slots. Magnets are mounted inside the rotor's magnet slots, and non-magnetic inserts are mounted inside the rotor's insert slots. One or more poles of each laminate includes a structural web that extends radially through the magnet and insert slots of that pole. Multiple poles of each rotor laminate lack a radially extending structural web. Each rotor laminate is rotated with respect to a neighboring rotor laminate such that each pole with a structural web axially aligns with a pole without a structural web.
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Patent Agency Ranking
公开(公告)号：US11220977B2
公开(公告)日：2022-01-11
申请号：US16539517
申请日：2019-08-13
Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
Inventor： Anthony M. Coppola , Peter P. Andruskiewicz, IV , Bradley A. Newcomb , Su Jung Han , Seongchan Pack
Abstract: A linerless engine block includes a polymer matrix composite having an internal surface that defines a bore. The polymer matrix composite has a first thermal conductivity at the internal surface of at least 5 W/m·° C. The linerless engine block also includes a first bond coating disposed on the internal surface within the bore, and a second wear-resistant coating disposed on the first bond coating within the bore such that the second wear-resistant coating is adhered to the polymer matrix composite by the first bond coating. A method of forming the linerless engine block is also described.
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57.发明授权公开(公告)号：US11207982B2
公开(公告)日：2021-12-28
申请号：US16710772
申请日：2019-12-11
Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
Inventor： Ming Liu , Anthony M. Coppola , Kestutis A. Sonta
IPC: B60L15/20 , B60L1/02 , B60L50/64 , B60L53/22 , H01M10/6556 , H01M10/6552 , H01M10/613 , H01M10/625 , B60L53/12
Abstract: Presented are electronic power module assemblies with direct-cooling heat pipe systems, methods for making/using such power module assemblies, and vehicles equipped with such power module assemblies. A power module assembly includes an outer housing with an internal coolant chamber that circulates therethrough a coolant fluid. A sidewall of the module's housing defines therethrough multiple coolant windows that fluidly connect to the coolant chamber. A power semiconductor switching device is mounted to the module housing, fluidly sealed to a first coolant window with the power device's inboard surface exposed to the coolant fluid. The power device is operable to modify electric current transmitted between a power source and an electrical load. A heat pipe with an outer casing has a first casing segment thereof mounted to an outboard surface of the power device, and a second casing segment fluidly sealed to a second coolant window and exposed to the coolant fluid.
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公开(公告)号：US20210211025A1
公开(公告)日：2021-07-08
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
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.
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59.发明申请公开(公告)号：US20210178902A1
公开(公告)日：2021-06-17
申请号：US16710772
申请日：2019-12-11
Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
Inventor： Ming Liu , Anthony M. Coppola , Kestutis A. Sonta
IPC: B60L1/02 , B60L50/64 , B60L15/20 , B60L53/22 , H01M10/625 , H01M10/6556 , H01M10/6552 , H01M10/613
Abstract: Presented are electronic power module assemblies with direct-cooling heat pipe systems, methods for making/using such power module assemblies, and vehicles equipped with such power module assemblies. A power module assembly includes an outer housing with an internal coolant chamber that circulates therethrough a coolant fluid. A sidewall of the module's housing defines therethrough multiple coolant windows that fluidly connect to the coolant chamber. A power semiconductor switching device is mounted to the module housing, fluidly sealed to a first coolant window with the power device's inboard surface exposed to the coolant fluid. The power device is operable to modify electric current transmitted between a power source and an electrical load. A heat pipe with an outer casing has a first casing segment thereof mounted to an outboard surface of the power device, and a second casing segment fluidly sealed to a second coolant window and exposed to the coolant fluid.
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公开(公告)号：US20210162688A1
公开(公告)日：2021-06-03
申请号：US16701693
申请日：2019-12-03
Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
Inventor： Anthony M. Coppola , Nicole Ellison
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.
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