Patents Assigned to BorgWarner, Inc.
  • Distributed cascaded winding for electric machines
    Patent number: 11038391
    Abstract: A stator includes a cylindrical core with a plurality of longitudinally extending slots, a first winding set formed as a first cascaded wire in two radial layers of the slots, a second winding set formed as a second cascaded wire in two other radial layers of the slots, and a jumper connecting the first and second wires. A first winding set may have three cascaded phase wires in first and second layers of the slots, and a second winding set may have three cascaded phase wires in third and fourth layers of the slots. A winding set of a first phase may have a first cascaded wire in two radial layers of a first one of the slots, and a winding set of a second phase may have a second cascaded wire in two other radial layers of the first one of the slots.
    Type: Grant
    Filed: September 20, 2018
    Date of Patent: June 15, 2021
    Assignee: BorgWarner Inc.
    Inventor: Kirk Neet
  • Dual volute turbocharger and system including the same
    Patent number: 11028765
    Abstract: A system includes a dual volute turbocharger and a controller. The dual volute turbocharger includes a turbine housing. The turbine housing includes a wall, a valve seat, and an interior surface defining a turbine housing interior, a first volute, a second volute, and a turbine housing outlet. The dual volute turbocharger also includes at least one valve member engageable with at least one of the valve seat and the wall of the turbine housing. The at least one valve member and the wall of the turbine housing collectively define a first cross-sectional flow area. The at least one valve member and the valve seat of the turbine housing collectively define a second cross-sectional flow area. The controller is adapted to control the at least one valve member to have an area ratio constant operating range according to a brake-specific fuel consumption of the internal combustion engine.
    Type: Grant
    Filed: February 13, 2020
    Date of Patent: June 8, 2021
    Assignee: BorgWarner Inc.
    Inventors: Michael Daniel Cola, Sascha Weiske, Mehul Sonigra
  • Distributed stator winding having parallel paths with crossing end loops
    Patent number: 11025117
    Abstract: An electric machine includes a stator core having a plurality of slots formed therein and a winding positioned in the slots of the stator core. The winding includes eight parallel paths distributed in layers of the stator core. The eight parallel paths include four pairs of adjacent paths. A first pair of adjacent paths crisscrosses a second pair of adjacent paths in the layers of the stator core. A third pair of adjacent paths crisscrosses a fourth pair of adjacent paths in the layers of the stator core. Neither the first pair nor the second pair of adjacent paths crisscrosses one or both of the third pair and the fourth pair of adjacent paths in the layers of the stator core.
    Type: Grant
    Filed: January 28, 2019
    Date of Patent: June 1, 2021
    Assignee: BorgWarner Inc.
    Inventor: Kirk Neet
  • Transfer case with range and mode actuator having cam follower mechanism to overcome blocked shift events and sensor configuration permitting detection of fork positions
    Patent number: 11021057
    Abstract: A transfer case with an actuator for operating a two-speed transmission (i.e., range mechanism) and a clutch (i.e., mode mechanism). The actuator employs a motor-driven cam structure that coordinates the movement of a first fork, which is associated with the range mechanism, and a second fork that is associated with the mode mechanism. A resilient coupling is employed to provide compliance between the motor and the cam structure in the event that tooth-on-tooth contact inhibits the range mechanism from changing from a high-range mode and a low range mode. Compliance is provided between the cam structure and the second fork in the event that tooth-on-tooth contact inhibits the mode mechanism from changing from a 2WD mode to a 4WD mode. A sensor system identifies the placement of the first and second forks in various positions and responsively generates associated sensor signals.
    Type: Grant
    Filed: April 4, 2018
    Date of Patent: June 1, 2021
    Assignee: BorgWarner Inc.
    Inventors: Abhinav Jain, Stephen D. Tucker, Travis J. Wentz
  • ROTOR BALANCE RING AND OIL FLINGER
    Publication number: 20210159760
    Abstract: A turbocharger includes a rotor rotatably mounted within the turbocharger about a rotor axis, a balance ring provided at an axial end of the rotor, and a cutout provided in the balance ring, the cutout having an open end extending radially outward from the rotor axis.
    Type: Application
    Filed: November 25, 2019
    Publication date: May 27, 2021
    Applicant: BorgWarner Inc.
    Inventors: Kurtis E. Henderson, Michael Sean Ward
  • Mechanism for locking a variable cam timing device
    Patent number: 11015491
    Abstract: A lock pin for a VCT device that has a locked position, locking a housing assembly relative to a rotor assembly of the variable cam timing device, and an unlocked position. The lock pin has a body comprising a first diameter with a first area, a second diameter with a second area, and a chamber formed between the first area of the first diameter and the second area of the second diameter for receiving fluid, the first area being greater than the second area. When fluid is applied to the chamber through the variable cam timing phaser, a difference between first area and the second area defining the chamber creates a force imbalance, such that the oil pressure applied to the chamber of the body assists in maintaining the Sock pin in the locked position.
    Type: Grant
    Filed: August 23, 2017
    Date of Patent: May 25, 2021
    Assignee: BorgWarner Inc.
    Inventors: Jared D. Nichols, Won-Jung Kwon
  • Electric machine with stator windings having over-under end loops
    Patent number: 11018541
    Abstract: A multi-phase electric machine having plurality of windings are mounted on the stator core and define a plurality of phases with each phase having at least two parallel windings. A standard pitch is defined between each pole of each phase, the pitch being a common circumferential spacing between corresponding slots of each pole. Each of the windings has a position change end loop at the same location, wherein the position change end loops define a non-standard pitch to thereby change the relative positions of the parallel windings in the slots. At each set of such position change end loops, the windings defining a greater pitch extend over the windings defining a lesser pitch.
    Type: Grant
    Filed: July 18, 2017
    Date of Patent: May 25, 2021
    Assignee: BorgWarner Inc.
    Inventors: Kirk E. Neet, Timothy J. Sailors
  • Vehicle drivetrain component having an internal vent relocation tube for venting a housing of the vehicle drivetrain component
    Patent number: 11015699
    Abstract: A driveline power transmitting component having a power transfer assembly disposed in a housing. The housing defines a vent aperture and a sump. A lubricating fluid is disposed in the sump and portions of the power transfer assembly travel through the lubricating fluid so that a lubrication surge zone and a splash lubrication zone are formed. The vent aperture is disposed in at least one of the surge zone, the splash lubrication zone and the sump when the driveline power transmitting component is disposed in at least one orientation in a predetermined range of operating positions in which the driveline power transmitting component can be operated. A breather relocation conduit is employed to permit air to be vented from the housing to the vent aperture without intaking lubricating fluid into the breather relocation conduit.
    Type: Grant
    Filed: July 24, 2018
    Date of Patent: May 25, 2021
    Assignee: BorgWarner Inc.
    Inventors: Arie Alexiou, Jeffrey Elder, Ian D. Worcester, Hongtao Wang
  • Turbine waste heat recovery expander with passive method for system flow control
    Patent number: 11015489
    Abstract: A waste heat recovery system for recovering rejected heat of an internal combustion engine includes a turbine expander. The turbine expander outputs power based on a working fluid and includes a turbine blade that is rotatable by the working fluid, a shaft that is coupled to and rotatable by the turbine blade and extends along a longitudinal axis, and a nozzle assembly for directing the working fluid to the turbine blade for rotating the turbine blade. The nozzle assembly includes a nozzle housing disposed about the shaft and adjacent the turbine blade, and a nozzle for accelerating the working fluid. The nozzle component defines a nozzle throat having a geometrical configuration. The waste heat recovery system further includes a passive control coupled to the nozzle component for directing the working fluid.
    Type: Grant
    Filed: March 20, 2020
    Date of Patent: May 25, 2021
    Assignee: BorgWarner Inc.
    Inventors: Frederick Michael Huscher, Paul Anschel
  • Torsional vibration damper and arrangement for the drivetrain of a motor vehicle with such a torsional vibration damper
    Patent number: 11015673
    Abstract: The present invention relates to a torsional vibration damper (18) comprising a first component (20) and a second component (22) which are torsionally elastically coupled to one another, wherein a force transmission device (26) is provided for transmitting an actuating force from the one axial side (48) of the torsional vibration damper (18) to the opposite axial side (50) of the torsional vibration damper (18) to a device (54) to be actuated. In addition, the present invention relates to an arrangement (2) for the drivetrain of a motor vehicle comprising such a torsional vibration damper (18).
    Type: Grant
    Filed: August 29, 2017
    Date of Patent: May 25, 2021
    Assignee: BorgWarner Inc.
    Inventors: Rupert Stephen Tull De Salis, Marco Guckelmus, Roshan Jethwa, Marco Valentin Kachler, Sebastian Zindel, Hans Juergen Hauck, Jochen Boeling
  • Balancing method for a turbocharger
    Patent number: 11008868
    Abstract: A method of balancing turbocharger rotating assembly (50) includes installing a shaft-and-turbine wheel subassembly (40) into a ball bearing cartridge (20) within a bearing housing (8) of a turbocharger (1), connecting a compressor wheel (5) to the shaft (6), and testing the balance of the turbocharger rotating assembly (50) while the turbocharger rotating assembly (50) is installed within the bearing housing (8) of the turbocharger (1). Based on the results of the balance testing, material is removed from the turbine wheel (4) while the shaft-and-turbine wheel subassembly (40) is installed within the bearing housing (8) of the turbocharger (1). The step of removing the material from the turbine wheel (4) comprises removing material from a peripheral edge (35) of a backwall (34) of the turbine wheel (4).
    Type: Grant
    Filed: January 14, 2019
    Date of Patent: May 18, 2021
    Assignee: BorgWarner, Inc.
    Inventor: Timothy Mark House
  • Camshaft phaser using both cam torque and engine oil pressure
    Patent number: 11002158
    Abstract: A variable cam timing phaser with a control valve that can selectively user either CTA mode, TA mode or both CTA and TA mode simultaneously to actuate the phaser.
    Type: Grant
    Filed: October 11, 2018
    Date of Patent: May 11, 2021
    Assignee: BorgWarner Inc.
    Inventor: Franklin R. Smith
  • Friction material
    Patent number: 10995810
    Abstract: A friction material has a first outermost surface and a second outermost surface spaced apart from the first outermost surface. The friction material includes a base which forms at least a portion of the first outermost surface. The base includes fibers present in an amount of from 20 to 80 weight percent, a filler present in an amount of from 20 to 80 weight percent, and a deposit which forms at least a portion of the second outermost surface and includes a friction adjusting agent. The friction material further includes a resin disposed throughout the friction material. The deposit is disposed in the friction material in a gradated pattern. At least a portion of the deposit is exposed to the environment and the second outermost surface has a surface roughness of from 2 to 11 micrometers as determined by non-contact laser measurement according to ISO 25178.
    Type: Grant
    Filed: May 31, 2019
    Date of Patent: May 4, 2021
    Assignee: BorgWarner Inc.
    Inventors: Deanna L. Miller Higgins, Feng Dong, Robert Lam
  • Electric machine with distributed winding having double cross end loops
    Patent number: 10998788
    Abstract: An electric machine a stator having a stator core and windings positioned thereon. The stator core has a plurality of slots formed therein and a winding positioned in the plurality of slots. The winding includes at least four parallel paths distributed in slot sets of the stator core. Each slot set includes at least four contiguous slots including two left slots and two right slots. A first parallel path and a second parallel path are arranged in the two left slots for at least a first revolution of the winding around the core. The first parallel path and the second parallel path are arranged in the two right slots for at least a subsequent revolution of the winding around the core.
    Type: Grant
    Filed: January 25, 2019
    Date of Patent: May 4, 2021
    Assignee: BorgWarner, Inc.
    Inventors: Kirk Neet, Tausif Husain
  • Actuation system having face cam mechanism operated by a planetary gear set
    Patent number: 10994609
    Abstract: An actuation system of a transfer case includes a face cam, a motor, a gear reduction assembly, and an intermediate rotating member. The face cam includes a first member and a second member, and rotation of the first member relative to the second annular causes the first member or the second annular member to displace axially relative to the other member for selective operation of a torque transfer mechanism of the torque transfer device. The gear reduction assembly includes a first planetary gear set that increases torque from the motor by a first ratio, and a second planetary gear set that increases torque from the first planetary gear set by a second ratio and is coaxial with the first planetary gear set and the motor. The intermediate rotating member is rotated by the gear reduction assembly and rotates the first annular member for selective operation of the torque transfer mechanism.
    Type: Grant
    Filed: April 24, 2018
    Date of Patent: May 4, 2021
    Assignee: BorgWarner Inc.
    Inventors: Mallikarjun Rudagi, Abhinav Jain, Sathya Vaidyanathan
  • Electro-mechanical on demand (EMOD) transfer case—dual drive gear and shift fork consolidation
    Patent number: 10988022
    Abstract: A dual drive gear of an actuation assembly for a transfer case includes an annular disk, a dual drive gear hub, and a sense plate. The annular disk has an inner periphery and an outer periphery. The outer periphery defines a plurality of teeth projecting radially outward. The dual drive gear hub is attached to the inner periphery of the annular disk and has an inner surface that defines a bore extending through a center of the dual drive gear. The dual drive gear hub includes a pair of curved walls projecting from a first axial end face of the annular disk. The sense plate projects from a second axial end face of the annular disk opposite of the first axial end face and includes a plurality of curved wall sections. The annular disk, the dual drive gear hub, and the sense plate are formed together as a single piece.
    Type: Grant
    Filed: February 12, 2019
    Date of Patent: April 27, 2021
    Assignee: BorgWarner Inc.
    Inventors: Larry A. Pritchard, Gurmeet Singh Bedi
  • Friction material
    Patent number: 10989263
    Abstract: A friction material presents a friction generating surface and a bonding surface facing opposite said friction generating surface. The friction material includes structural fibers, friction particles, polyvinyl alcohol fibers, and a resin. A method of forming the friction material is also disclosed. The method comprises the steps of: combining the structural fibers, the friction particles, and the polyvinyl alcohol fibers having an average diameter of less than about 11 ?m, an average length of less than about 4 mm, an average denier of less than about 1, to form a substrate material; impregnating the substrate material with the resin; and curing the resin to form the friction material.
    Type: Grant
    Filed: November 15, 2016
    Date of Patent: April 27, 2021
    Assignee: BorgWarner Inc.
    Inventors: Jason Bares, Feng Dong, Robert Lam, Wanjun Liu
  • Vehicle driveline component having a lubricant pathway for transmitting a lubricating fluid to desired location
    Patent number: 10989296
    Abstract: A vehicle driveline component having a housing, a shaft received in the housing, a lubricant pathway coupled to the shaft for rotation therewith, a sleeve disposed coaxially about the lubricant pathway, and a fluid feed conduit coupled to the component housing. The lubricant pathway is disposed helically about an exterior surface of the shaft. The sleeve has a feed port. The fluid feed conduit having an outlet that is in fluid communication with the feed port. Lubricant in the lubricant pathway that has been discharged from the outlet of the fluid feed conduit travels in a predetermined axial direction along the rotary axis of the shaft when the shaft rotates about the rotary axis in a predetermined rotational direction.
    Type: Grant
    Filed: September 21, 2020
    Date of Patent: April 27, 2021
    Assignee: BorgWarner Inc.
    Inventors: Arie Alexiou, Jason P. Eldred, Ian D. Worcester, Hongtao Wang, Gurmeet Singh Bedi
  • Electric charging device with fluid cooling
    Patent number: 10971974
    Abstract: A charging device for an internal combustion engine with a shaft, a compressor wheel arranged on the shaft, a stator housing and a stator. The stator is arranged within the stator housing. A rotor is arranged on the shaft and a cooling channel for accommodating a coolant extends axially between the stator housing and the stator. A split tube is provided between the rotor and stator. A first seal is provided in the axial direction between the stator housing and a first end of the stator and a second seal is provided in the axial direction between the stator housing and a first end of the split tube. Alternatively to the split tube, a separation tube is arranged between the stator and the stator housing so that the cooling channel is formed in the radial direction between the separation tube and the stator housing.
    Type: Grant
    Filed: April 26, 2017
    Date of Patent: April 6, 2021
    Assignee: BorgWarner Inc.
    Inventor: Christoph Rachor
  • Turbocharger with adjustable vanes
    Patent number: 10968768
    Abstract: A turbocharger (1) with variable turbine geometry (VTG). A multiplicity of guide vanes (7) each have a vane shaft (8) mounted in the vane bearing ring (6). An adjusting ring (5) is operatively connected to the guide vanes (7) by way of associated vane levers (20) which are fastened to the vane shafts (8) at one of their ends. Each vane lever (20) has, at the other end, a lever head (23) which can be placed in engagement with an associated engagement recess (24) of the adjusting ring (5). An actuation device (11) has an inner lever (26) which is arranged in the turbine housing (2) and which is connected by means of an adjustment pin (25) to the adjusting ring (5). The adjustment pin (25) has a welding bolt (27) on which a wear-resistant sleeve (28) is arranged.
    Type: Grant
    Filed: June 17, 2015
    Date of Patent: April 6, 2021
    Assignee: BorgWarner Inc.
    Inventor: Thomas Ramb