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公开(公告)号：US20230070394A1
公开(公告)日：2023-03-09
申请号：US17445739
申请日：2021-08-24
Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
Inventor： Alireza Fatemi , Anthony M. Coppola , Derek F. Lahr , Alan G. Holmes
Abstract: Rotor for electric machines and methods for fabricating rotors for electric machines are provided. An exemplary method includes assembling a stack of laminations to form a rotor core having an external surface. The rotor core defines one to five layers of internal cavities and an interior permanent magnet is positioned in a selected internal cavity. The method also includes locating a non-magnetic structural element in the selected internal cavity. Further, the method includes applying a compressive force on the external surface of the rotor core with an annular sleeve.
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公开(公告)号：US20220140680A1
公开(公告)日：2022-05-05
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
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.
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公开(公告)号：US11223252B2
公开(公告)日：2022-01-11
申请号：US16531631
申请日：2019-08-05
Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
Inventor： Anthony M. Coppola , Gayatri V. Dadheech , Alireza Fatemi
Abstract: An electric machine is described, and includes a rotor that is rotatably disposed in a stator. The rotor includes a rotatable shaft that is disposed on a longitudinal axis, and a plurality of laminations that are disposed on the rotatable shaft. The plurality of laminations are arranged on the rotatable shaft to form a plurality of axially-disposed cavities, wherein each of the cavities is defined by a surface. A coating is disposed on the surfaces of the cavities, and a curable filler material is introduced into each of the cavities. The curable filler material adheres to the plurality of laminations via the coating.
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公开(公告)号：US11171545B2
公开(公告)日：2021-11-09
申请号：US16662862
申请日：2019-10-24
Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
Inventor： Anthony M. Coppola , Alireza Fatemi , Bradley A. Newcomb , Derek F. Lahr , Sean R. Wagner
Abstract: A stator assembly for an electric motor includes a laminate steel core arranged on an axis. The stator assembly also includes a fluid inlet and a fluid outlet. The stator assembly additionally includes a stator housing arranged on the axis concentrically with respect to the laminate steel core. The stator housing has a conduit fluidly connected to each of the fluid inlet and the fluid outlet and configured to circulate fluid around the laminate steel core. The stator assembly also includes a structural skeleton embedded in the stator housing. The structural skeleton is thereby configured to reinforce the stator housing. An electric motor employing the above-described stator assembly is also contemplated.
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公开(公告)号：US20210126511A1
公开(公告)日：2021-04-29
申请号：US16662862
申请日：2019-10-24
Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
Inventor： Anthony M. Coppola , Alireza Fatemi , Bradley A. Newcomb , Derek F. Lahr , Sean R. Wagner
Abstract: A stator assembly for an electric motor includes a laminate steel core arranged on an axis. The stator assembly also includes a fluid inlet and a fluid outlet. The stator assembly additionally includes a stator housing arranged on the axis concentrically with respect to the laminate steel core. The stator housing has a conduit fluidly connected to each of the fluid inlet and the fluid outlet and configured to circulate fluid around the laminate steel core. The stator assembly also includes a structural skeleton embedded in the stator housing. The structural skeleton is thereby configured to reinforce the stator housing. An electric motor employing the above-described stator assembly is also contemplated.
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Patent Agency Ranking
公开(公告)号：US20210047980A1
公开(公告)日：2021-02-18
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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7.发明授权公开(公告)号：US11658525B2
公开(公告)日：2023-05-23
申请号：US17066520
申请日：2020-10-09
Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
Inventor： Anthony M. Coppola , Alireza Fatemi , William T. Ivan , Song He , Yew Sum Leong
CPC classification number: H02K1/185 , H02K1/20 , H02K9/19 , H02K11/014 , H02K15/028 , H02K15/12
Abstract: An electric motor assembly includes a housing having a generally cylindrical inner surface defining a generally cylindrical cavity within the housing, a stator operatively disposed within the generally cylindrical cavity, the stator including a plurality of stacked laminations wherein each lamination has an outer circumferential edge and a plurality of finger elements extending inward, and a layer of polymer disposed between a generally cylindrical outer surface of the stator and the generally cylindrical inner surface of the housing, such that the stator is fastened to the housing by the polymer. A method of manufacturing the electric motor assembly includes disposing a stator within a housing such that a gap is defined between the stator and the housing and the stator is not directly connected to the housing, and substantially filling the gap with a polymer capable of fastening the stator to the housing by only the polymer.
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公开(公告)号：US20230054794A1
公开(公告)日：2023-02-23
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
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.
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公开(公告)号：US20220230938A1
公开(公告)日：2022-07-21
申请号：US17152084
申请日：2021-01-19
Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
Inventor： Anthony M. Coppola , Alireza Fatemi , Ronald O. Grover, JR. , Ming Liu , Chih-hung Yen
IPC: H01L23/473 , H01L21/48
Abstract: A vascular jet cooling system for use with a planar power module and a coolant supply includes a manifold housing and one or more jet impingement plates. The manifold housing is constructed of a dielectric polymer molding material, and defines a coolant inlet port configured to fluidly connect to the coolant supply, an internal cavity in fluid communication with the coolant inlet port and containing the power module, and a coolant outlet port in fluid communication with the internal cavity. The jet impingement plate(s) is arranged in the internal cavity. Openings of the plates direct coolant passing through the coolant inlet port onto a respective major surface of the power module. A power module assembly includes a planar power module and the vascular jet cooling system. A method of constructing the power module assembly uses sacrificial materials and overmolding of the jet impingement plates.
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公开(公告)号：US20220224206A1
公开(公告)日：2022-07-14
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 , H01L23/473 , H01L23/50 , H02K7/00 , H02K11/00 , B60L50/60
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.
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