Abstract:
A number of variations may include a vehicle which may have a vehicle body and a vehicle hub operably coupled to the vehicle body. A vehicle wheel may be operably coupled to the vehicle hub. The vehicle wheel may be isolated from the vehicle hub by at least one isolation feature selected from the group consisting of: an extended flange portion of the vehicle wheel may be disposed between a pilot hole and the vehicle hub, a multiple piece cover portion may fully cover the pilot hole, a drain slot may be disposed on the vehicle wheel and the drain slot may have a slope of at least five degrees, or an enhanced bushing may create a non-flat profile between the vehicle wheel and a fixation device.
Abstract:
A leg of a power converter includes: a first one of (a) a first power module and (b) a first die, the first one including a high side switch having a first terminal configured to be connected to a first direct current (DC) busbar having a first potential; and a second one of (a) a second power module and (b) a second die, the second one including a low side switch having a first terminal configured to be connected to a second DC busbar having a second potential that is different than the first potential; and an alternating current (AC) busbar disposed vertically (a) between the first one and the second one and (b) between the first DC busbar and the second DC busbar.
Abstract:
An axial flux motor assembly is disclosed and includes: an axial flux motor comprising a rotor, and a first stator; and a power inverter assembly. The power module assembly includes: a printed circuit board; a control module mounted on the printed circuit board; power module assemblies connected to the printed circuit board and controlled by the control module; and a cold plate. The cold plate is disposed between the first stator and the power module assemblies and includes a first side and a second side, which is opposite the first side. The cold plate cools the power module assemblies via the first side and the first stator via the second side.
Abstract:
A power module includes: a first substrate layer that is disposed on a first plane; a second substrate layer that is disposed on a second plane that is parallel to the first plane; first and second electrical conductors that are configured to be electrically connected to first and second direct current (DC) reference potentials, respectively, and that extend outwardly from the power module on a third plane that is parallel to the first and second planes; third, fourth, and fifth electrical conductors that are configured to be electrically connected to first, second, and third alternating current (AC) reference potentials, respectively, and that extend outwardly from the power module on a fourth plane that is parallel to the first, second, and third planes; and a plurality of dies of switches, respectively, disposed between the first and second substrate layers.
Abstract:
A power module is provided and includes first stack, second stack, and third stacks of layers, a heat pipe, and at least one cold plate or heat sink. The third stack of layers is disposed between the first stack of layers and the second stack of layers and includes a first semiconductor die, a second semiconductor die and a center spacer layer disposed between the first semiconductor die and the second semiconductor die. The heat pipe extends at least partially into the center spacer layer. The at least one cold plate or heat sink receives thermal energy from the first stack of layers and the second stack of layers. The second stack of layers, the third stack of layers, the heat pipe and the at least one cold plate or heat sink facilitate dual sided cooling of each of the first semiconductor die and the second semiconductor die.
Abstract:
A metal workpiece, such as a wheel, and a method of providing an enhanced corrosion resistant surface coating on an exposed surface of a metal or alloy substrate (such as magnesium). A corrosion resistance basecoat is formed, including generating an oxide layer, and applying a first primer coating onto at least a portion of the oxide layer. The method may further include identifying highest corrosion prone areas on the substrate and designing a support rack that avoids contact with these corrosion prone areas. The method also includes forming a topcoat over at least a portion of the basecoat, by applying a second primer coating onto at least a portion of the first primer coating and depositing a sputtered metallic film onto the second primer coating using a physical vapor deposition technique. A clear coat layer may be applied over the metallic film.
Abstract:
A cooling system includes a housing including a base portion with sides and a bottom surface that define a cavity and a cover portion to enclose the base portion and including cooling members attached thereto. A shield is arranged in the cavity. A vertical member is arranged below the shield to define a first fluid chamber between one side of the vertical member and one side of the base portion and a second fluid chamber between an opposite side of the vertical member and another side of the base portion. The electronic components are arranged in the second fluid chamber. Cooling fluid is arranged in the cavity and has a fluid level below at least a portion of the shield. The housing is mounted at an inclined angle relative to horizontal or the housing is mounted parallel to horizontal and the shield is mounted at the inclined angle.
Abstract:
A cooling system includes a housing configured to enclose an electric vehicle component immersed in cooling fluid and to define a first volume. A variable volume member defines a second volume that varies in response to a first signal. A combined volume is defined by the first volume and the second volume. Heat causes the cooling fluid to transition between a liquid state and a vapor state in the combined volume. A pressure sensor is configured to sense a pressure in the combined volume. A condenser is configured to cause the cooling fluid to transition from the vapor state back to the liquid state. A controller includes a volume adjustment module configured to generate the first signal to vary the second volume of the variable volume member to adjust the combined volume in response to the pressure and a first temperature of the electric vehicle component.
Abstract:
Customizable methods of protecting select regions of a light metal or alloy workpiece, such as a wheel (10), from corrosion are provided. The light metal or alloy may be magnesium, aluminum, or titanium. A first region (50) of the exposed surface (40) is identified that has increased exposure to corrosive agents in an external environment (in service conditions) as compared to a second region (52). Thus, a corrosion resistant coating is selectively formed over the first region (50) of the exposed surface (40). The second region (52) may have a second distinct corrosion resistant coating. Methods for selectively and efficiently forming such corrosion resistant systems are provided. In certain methods, the locations where the corrosion resistant coating is applied are controlled by immersing only select portions of or selectively masking the workpiece in a micro-arc oxidation electrolyte bath. In other methods, the thicknesses of the coatings are locally tailored by controlling the electric field.