Abstract: A power feeder device can include a base having a mounting portion and a plurality of connector structures extending from the mounting portion and spaced apart relative to each other to form a respective gap therebetween. Each connector structure can be configured to receive a respective pair of terminals to electrically connect the respective pair of terminals within connector structures and to block a line of sight between an adjacent pair of terminals. The device can also include a cover configured to mate with the base to enclose each of the plurality of connector structures and to increase a length of a creepage path between each pair of terminals by at least partially inserting into each gap between the connector structures. The base and the cover can be configured to form a terminal opening on each lateral side when assembled to allow pass-through of a conductor and/or portion of each terminal.

Abstract: A power feeder device can include a base having a mounting portion and a plurality of connector structures extending from the mounting portion and spaced apart relative to each other to form a respective gap therebetween. Each connector structure can be configured to receive a respective pair of terminals to electrically connect the respective pair of terminals within connector structures and to block a line of sight between an adjacent pair of terminals. The device can also include a cover configured to mate with the base to enclose each of the plurality of connector structures and to increase a length of a creepage path between each pair of terminals by at least partially inserting into each gap between the connector structures. The base and the cover can be configured to form a terminal opening on each lateral side when assembled to allow pass-through of a conductor and/or portion of each terminal.

Abstract: An electronics assembly including a motor controller electronics arrangement includes a housing enclosing a solid-state switch array, a cold plate arranged within the housing and in thermal communication with the solid-state switch array, and a feeder cable. The feeder cable is electrically connected to the solid-state switch array, has a coolant jacket extending thereabout, is separated from the switch arrangement by the housing, and is in liquid communication with the cold plate to limit heat communicated by the feeder cable into the housing. Electrical systems and methods of cooling feeder cables are also described.

Abstract: A system for reducing low cycle fatigue of a soldered connection includes a controller and a heating element operatively connected to the controller. The system also includes a printed wire board soldered in connection with an electronic component. The controller is configured to retrieve a signal indicative of a temperature of the electronic component, and compare the temperature to a stored predetermined range of operating temperatures. Responsive to determining that the temperature of the electronic component is less than a lower threshold temperature of the predetermined range of operating temperatures, the controller transmits a signal to the heating element that causes the heating element to heat the electronic component. The controller then saves, to an operatively connected computer readable memory, a magnitude of temperature difference and a number of times that magnitude is reached. The controller uses the stored information to track the life of the electronic component.

Abstract: A contactor post for an electrical contactor may comprise a body comprising an electrically and thermally conductive material, and a heat sink shunt extending from the body and comprising the electrically and thermally conductive material, wherein the body and the heat sink shunt are comprised of a single piece of the electrically and thermally conductive material.

Abstract: A contactor assembly post is provided. The contactor assembly post includes a first portion electrically connected to an external bus bar at an exterior of an electrical contactor housing, a second portion electrically connected to an internal bus bar at the exterior of the electrical contactor housing, a third portion and fins. The internal bus bar is configured to extend into an interior of the electrical contactor housing to be electrically coupled to another internal bus bar. The third portion extends transversely between the first and second portions. The fins extend transversely from multiple points defined along a longitudinal axis of the third portion.

Abstract: A contactor post for an electrical contactor may comprise a body comprising an electrically and thermally conductive material, and a heat sink shunt extending from the body and comprising the electrically and thermally conductive material, wherein the body and the heat sink shunt are comprised of a single piece of the electrically and thermally conductive material.

Abstract: A fluid cooled cold plate includes a main coolant passage with a first cross-sectional area taken laterally in a direction perpendicular to the flow direction and a finned coolant passage having a second cross-sectional area taken laterally in a direction perpendicular to the flow direction, with the second area smaller than the first area. Fluidly connecting the main coolant passage with the finned coolant passage is a branch oriented such that a fluid is turned 90° or more when passing into the branch from the main coolant passage. Also included is a coolant bypass passage in fluid communication with the main coolant passage and located fluidically parallel to the finned coolant passage.

Abstract: A contactor assembly post is provided. The contactor assembly post includes a first portion electrically connected to an external bus bar at an exterior of an electrical contactor housing, a second portion electrically connected to an internal bus bar at the exterior of the electrical contactor housing, a third portion and fins. The internal bus bar is configured to extend into an interior of the electrical contactor housing to be electrically coupled to another internal bus bar. The third portion extends transversely between the first and second portions. The fins extend transversely from multiple points defined along a longitudinal axis of the third portion.

Abstract: A system for reducing low cycle fatigue of a soldered connection includes a controller and a heating element operatively connected to the controller. The system also includes a printed wire board soldered in connection with an electronic component. The controller is configured to retrieve a signal indicative of a temperature of the electronic component, and compare the temperature to a stored predetermined range of operating temperatures. Responsive to determining that the temperature of the electronic component is less than a lower threshold temperature of the predetermined range of operating temperatures, the controller transmits a signal to the heating element that causes the heating element to heat the electronic component. The controller then saves, to an operatively connected computer readable memory, a magnitude of temperature difference and a number of times that magnitude is reached. The controller uses the stored information to track the life of the electronic component.

Abstract: A contactor assembly post is provided. The contactor assembly post includes a first portion electrically connected to an external bus bar at an exterior of an electrical contactor housing, a second portion electrically connected to an internal bus bar at the exterior of the electrical contactor housing, a third portion and fins. The internal bus bar is configured to extend into an interior of the electrical contactor housing to be electrically coupled to another internal bus bar. The third portion extends transversely between the first and second portions. The fins extend transversely from multiple points defined along a longitudinal axis of the third portion.

Abstract: A contactor assembly post is provided. The contactor assembly post includes a first portion electrically connected to an external bus bar at an exterior of an electrical contactor housing, a second portion electrically connected to an internal bus bar at the exterior of the electrical contactor housing, a third portion and fins. The internal bus bar is configured to extend into an interior of the electrical contactor housing to be electrically coupled to another internal bus bar. The third portion extends transversely between the first and second portions. The fins extend transversely from multiple points defined along a longitudinal axis of the third portion.

Abstract: In one exemplary embodiment, an electric machine includes a stator having a plurality of axial protrusions forming a plurality of stator cooling channels on a radially outer surface of the stator and a tapered portion located adjacent a distal end of at least one of the plurality of protrusions. Additionally, the disclosure includes a method for cooling the electric machine.

Abstract: A cold plate assembly is provided having a base defining a cooling channel and a heat exchanger friction-stir welded to the base, wherein the heat exchanger is located within a portion of the cooling channel, and the friction-stir welding between the heat exchanger and the base forms a fluid seal.

Abstract: In one exemplary embodiment, an electric machine includes a stator having a plurality of axial protrusions forming a plurality of stator cooling channels on a radially outer surface of the stator and a tapered portion located adjacent a distal end of at least one of the plurality of protrusions. Additionally, the disclosure includes a method for cooling the electric machine.

Abstract: A system for cooling an electronics box includes an electronics box with a first portion and a second portion. During a low load condition on the electronics box the first portion and the second portion require a substantially similar amount of cooling air and during a high load condition on the electronics box the second portion requires a substantially greater amount of cooling air than the first portion. The system further includes a first plenum in fluid communication with the first portion and a second plenum in fluid communication with the second portion. A normal cooling air supply is in fluid communication with both the first plenum and the second plenum during the low load condition on the electronics box, and a supplemental cooling air supply in fluid communication with the second plenum during the high load condition on the electronics box.

Abstract: A fluid cooled cold plate includes a main coolant passage with a first cross-sectional area taken laterally in a direction perpendicular to the flow direction and a finned coolant passage having a second cross-sectional area taken laterally in a direction perpendicular to the flow direction, with the second area smaller than the first area. Fluidly connecting the main coolant passage with the finned coolant passage is a branch oriented such that a fluid is turned 90° or more when passing into the branch from the main coolant passage. Also included is a coolant bypass passage in fluid communication with the main coolant passage and located fluidically parallel to the finned coolant passage.

Abstract: An electro-magnetic device includes a core having a first end that extends to a second end through an outer core surface and an inner core surface. A plurality of windings extend about the core, and a polymer housing covers the core and the plurality of windings. The polymer housing includes an outer housing member that extends adjacent to the outer core surface and an inner housing member that extends adjacent to the inner core surface.

Abstract: A core assembly for an electric motor includes a heat exchanger comprising a plurality of fins. The fins define a plurality of cooling air passages that include offset fins that disrupt cooling air flow to reduce the formation of boundary layers and improve heat transfer capacity.

Abstract: A solid state power control module contains non-volatile memory. A switch for opening is provided to break a supply of power to a component. The switch is operable to trip (open) when an undesirable condition is detected, and further to be opened upon receiving a control signal. A status of the switch is stored in the non-volatile memory. A detector is provided for identifying when a module has been mounted in a housing, and communicates with the non-volatile memory if it is determined that the module is newly installed in a housing. A system and method are also claimed.