公开(公告)号：US20230170772A1

公开(公告)日：2023-06-01

申请号：US17537123

申请日：2021-11-29

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Anthony Michael Coppola ,  Alireza Fatemi ,  Derek Frei Lahr ,  Kestutis A. Sonta ,  Alan G. Holmes

IPC: H02K15/02 ,  B29C65/56 ,  H02K1/2791

CPC classification number: H02K15/028 ,  B29C65/565 ,  H02K1/2791 ,  B29L2031/7498

Abstract: A rotor for an electric machine includes a rotor assembly having an outer surface and including a plurality of poles with permanent magnets. A solid layer is formed on the outer surface of the rotor assembly and has an outer surface with a first coefficient of friction that is lower than a second coefficient of friction of the outer surface of the rotor assembly. The rotor includes an outer sleeve. The rotor assembly is press-fit into the outer sleeve.

公开(公告)号：US20170365824A1

公开(公告)日：2017-12-21

申请号：US15392347

申请日：2016-12-28

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Elisabeth J. Berger ,  Kestutis A. Sonta

IPC: H01M2/02 ,  B32B7/12 ,  B32B15/04

Abstract: An example of a thermal composite includes a substrate, a primer layer, a first adhesive layer, a blanket layer, a second adhesive layer, and a metal layer. The blanket layer includes basalt fibers or glass fibers. The thermal composite may be incorporated into a battery pack as a battery enclosure.

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：US11545708B2

公开(公告)日：2023-01-03

申请号：US16686806

申请日：2019-11-18

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Kestutis A. Sonta ,  James W. Boswell, III

IPC: H01M50/124 ,  C08G59/18 ,  C08F2/50 ,  B32B7/023

Abstract: Methods for manufacturing a pouch-type battery cell include disposing one or more electrode pairs between a first aluminum pouch layer and a second aluminum pouch layer, sealing the first pouch layer and the second pouch layer to form a peripheral seal joining the first pouch layer and the second pouch layer to form a pouch with an outer edge encasing the anode and the cathode, applying a photocatalytic polymer coating precursor to the outer edge of the pouch, and photo-curing the photocatalytic polymer coating precursor to form a conformal edge coating. The photocatalytic polymer coating precursor includes one or more photo-initiators, one or more acrylates, and one or more polyamines. The polyamines can include tertiary amines including α-CH functional groups, diamines represented by the formula H2N—R—NH2, wherein R represents saturated and unsaturated aliphatic moieties, and N,N′-(2,2-dimethylpropylidene) hexamethylenediamine. The photo-initiators can include Diphenyl(2,4,6-trimethylbenzoyl) phosphine oxide, 2,2-Dimethoxy-2-phenylacetophenone, and p-tert-butylphenyl 1-(2,3)-epoxy)propyl ether.

公开(公告)号：US20210195808A1

公开(公告)日：2021-06-24

申请号：US16724998

申请日：2019-12-23

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Ming Liu ,  Anthony M. Coppola ,  Kestutis A. Sonta

IPC: H05K7/20 ,  B60L50/51 ,  B60L50/60

Abstract: Presented are electronic power module assemblies with direct-cooling vapor chamber 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 power semiconductor switching device is mounted to the module's housing, separated from the coolant chamber and isolated from the coolant fluid. The power device selectively modifies electric current transmitted between a power source and an electrical load. A two-phase, heat-spreading vapor chamber device includes an outer casing with a casing segment that is mounted to the module housing, fluidly sealed to the internal coolant chamber and exposed to the coolant fluid. Another casing segment includes an inboard-facing casing surface that is mounted to an outboard-facing surface of the power device, and an outboard-facing casing surface mounted to an inboard-facing surface of the power device.

公开(公告)号：US20240395438A1

公开(公告)日：2024-11-28

申请号：US18322211

申请日：2023-05-23

Applicant: GM Global Technology Operations LLC

Inventor： Yi Liu ,  Qigui Wang ,  Huaxin Li ,  Kestutis A. Sonta ,  Daniel J. Wilson

IPC: H01B1/02 ,  H01B1/04 ,  H01B5/08

Abstract: A conductive cable for a battery electric vehicle is provided. The conductive cable comprises a plurality of first members in alignment to define a longitudinal axis of the conductive cable. Each first member comprises a first conductive wire about which a first outer layer is disposed for electric current to flow therethrough relative to the longitudinal axis. The first outer layer comprises a first metal substrate having a first side and an opposite second side. The first outer layer comprises a first copper-graphene (Cu-Gr) multilayer composite disposed on the first side and a second Cu-Gr multilayer composite disposed on the second side of the first metal substrate. Each first conductive wire comprises a first metallic material. The plurality of first members is disposed together along the longitudinal axis to define a cable bundle. The conductive cable further comprises a non-conductive layer disposed about the cable bundle.

公开(公告)号：US20240339733A1

公开(公告)日：2024-10-10

申请号：US18296416

申请日：2023-04-06

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Yi Liu ,  Qigui Wang ,  Huaxin Li ,  Kestutis A. Sonta ,  Daniel J. Wilson

IPC: H01M50/526 ,  H01M50/507 ,  H01M50/571

CPC classification number: H01M50/526 ,  H01M50/507 ,  H01M50/571 ,  H01M2220/20

Abstract: A busbar for high conductivity distribution of electrical power within a power module of an electric vehicle (EV). The busbar may include a plurality of multilayer composites having copper-graphene laminations. One or more of the multilayer composite may include a first copper-graphene lamination having a plurality of graphene layers disposed between a plurality of copper layers, a second copper-graphene lamination having a plurality of graphene layers disposed between a plurality of copper layers, and a carrier substrate disposed relative to the first and second copper-graphene laminations.

公开(公告)号：US12062946B2

公开(公告)日：2024-08-13

申请号：US17374244

申请日：2021-07-13

Applicant: GM Global Technology Operations LLC

Inventor： Alireza Fatemi ,  Anthony Michael Coppola ,  Derek Frei Lahr ,  Kestutis A. Sonta

IPC: H02K1/28 ,  H02K1/32

CPC classification number: H02K1/28 ,  H02K1/32

Abstract: A rotor for an electric machine includes a rotor body formed from a plurality of stacked laminations defining a first axial end and an opposing second axial end. Each of the plurality of stacked laminations includes a plurality of openings that are aligned so as to define a plurality of passages through the rotor body. A plurality of reinforcement elements extend through the plurality of stacked laminations. Each of the plurality of reinforcement elements is arranged in a corresponding one of the plurality of passages and includes a first end portion and a second end portion. The first end portion and the second end portion of select ones of the plurality of reinforcement elements extend outwardly of the first axial end and the second axial end.

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

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

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：US20240421645A1

公开(公告)日：2024-12-19

申请号：US18337192

申请日：2023-06-19

Applicant: GM Global Technology Operations LLC

Inventor： Yi Liu ,  Qigui Wang ,  Huaxin Li ,  Kestutis A. Sonta ,  Daniel J. Wilson

IPC: H02K3/02 ,  H02K1/16

Abstract: A conductive composite stator unit for an electric motor of a vehicle is provided. The stator unit comprises a stator core comprising a body having a first core end and an opposing second core end. The stator unit further comprises a plurality of conductive bars extending from the first core end to the second core end. Each conductive bar comprises a straight portion disposed in one of the slots such that the respective conductive bar is in contact with the stator core. Each conductive bar comprising a central portion and an outer layer disposed thereabout for electrical current to flow therethrough relative to the longitudinal axis, the outer layer comprises at least two copper-graphene (Cu-Gr) layers. Each Cu-Gr layer comprises a copper layer and a graphene layer. The stator unit further comprises an insulator layer disposed about each of the plurality of conductive bars.