Abstract: A system includes an inverter configured to convert DC power from a battery to AC power to drive a motor, wherein the inverter includes: a power module, the power module including a thermistor assembly, the thermistor assembly including: a ceramic substrate; a thermistor element on the ceramic substrate; a protective coating disposed on the thermistor element so that the thermistor element is between the protective coating and the ceramic substrate; and a terminal electrode on the ceramic substrate, wherein an angle between a surface of the terminal electrode facing the protective coating and a surface of the protective coating facing the terminal electrode is greater than 90 degrees.

Abstract: A system includes: an alternating current (AC) to direct current (DC) converter (AC-DC converter) including: a bulk capacitor, and an AC-DC converter switch connectable to a line voltage; a DC to DC converter (DC-DC converter) connected to the AC-DC converter, the DC-DC converter including: one or more transformers having a secondary side connectable to a battery, and a bridge driver connected to a primary side of the one or more transformers, the bridge driver including a bridge driver switch; and one or more controllers configured to control an operation of the bridge driver switch to control a discharge of the bulk capacitor to the battery at an end of a grid-to-battery operation, the grid-to-battery operation to supply electric power from the line voltage to the battery.

Abstract: A system includes: a bidirectional alternating current (AC) to direct current (DC) converter (AC-DC converter) connectable to a line voltage and a battery, the AC-DC converter including: one or more leaves connectable to the line voltage and the battery, the one or more leaves configured to receive DC voltage from the battery and generate AC voltage for the line voltage, and a neutral leaf connectable to the line voltage and the battery, the neutral leaf configured to provide a return path for the generated AC voltage from the line voltage to the AC-DC converter; and one or more controllers configured to control an operation of the one or more leaves and the neutral leaf to control the AC voltage.

Abstract: A system includes: an inverter configured to convert DC power from a battery to AC power to drive a motor, wherein the inverter includes: a bulk capacitor; one or more switches; a gate driver; and one or more controllers, wherein the one or more controllers are configured to provide one or more of a gate voltage or a pulse width modulated (PWM) signal to the gate driver to control the one or more switches to discharge the bulk capacitor.

Abstract: Disclosed solutions relate to electrical inverters. In an example, an inverter to convert DC power from a voltage source to AC power to drive a motor is disclosed. The inverter includes a first power module. The first power module includes first phase switches, second phase switches and positive DC power tabs connected to a positive DC rail to provide positive DC power to the first phase switches and the second phase switches. The inverter further includes negative DC power tabs connected to a negative DC rail to provide negative DC power to the first phase switches and the second phase switches. The inverter further includes first phase AC power tabs to receive AC power from the first phase switches. The inverter further includes second phase AC power tabs to receive AC power from the second phase switches.

Abstract: A system includes: an inverter configured to convert DC power from a battery to AC power to drive a motor, wherein the inverter includes: a bulk capacitor; one or more phase switches; and one or more controllers configured to control a gate voltage to the one or more phase switches to discharge the bulk capacitor, wherein the one or more controllers is configured to control the gate voltage based on one or more of a measured temperature of the one or more phase switches or an estimated temperature of the one or more phase switches.

Abstract: A system includes a power module, wherein the power module includes a first interlocking feature on a first surface of the power module; and at least one heat sink, wherein the at least one heat sink includes a second interlocking feature on a surface of the at least one heat sink, wherein the surface of the at least one heat sink includes a layer of thermal interface material.

Abstract: A system includes a rotor core; a rotor stack extending circumferentially from the rotor core, the rotor stack including: a first end; a second end opposite to the first end; and a first slot in the rotor stack, the first slot extending from the first end to the second end; and a hairpin cooling pipe in the first slot of the rotor stack.

Abstract: A system includes: an inverter configured to convert DC power to AC power, wherein the inverter includes: a power module including: a flex layer including a gate trace providing an electrical connection to a gate input connection of the power module, a first substrate, a second substrate including a source plane, the source plane including a step trench, a semiconductor die disposed between the first substrate and the second substrate, the step trench formed in a portion of the source plane corresponding to at an edge of the semiconductor die, and the semiconductor die including a gate connected to the gate trace, and a sinter element disposed between the semiconductor die and the second substrate to connect the semiconductor die to the second substrate; a battery configured to supply the DC power to the inverter; and a motor configured to receive the AC power from the inverter.

Abstract: An inverter may include a housing having a body and a protruding rim extending from the body, wherein the protruding rim surrounds a cavity that extends through to the body. An inverter may include one or more electrical receptacles, wherein the one or more electrical receptacles are disposed within the cavity such that a portion of at least one of the one or more electrical receptacles extends above the protruding rim. An inverter may include a metal sheet, wherein the metal sheet is molded to an inner surface of the protruding rim such that the protruding rim extends past the metal sheet, and wherein the metal sheet circumferentially surrounds the cavity.

Abstract: An apparatus includes a controller configured to: determine whether a first current measurement, a second current measurement, and a third current measurement are balanced; in response to a determination that the first current, the second current, and the third current are balanced, determine a weight factor; determine a product of a direct current voltage output measurement, the weight factor, a first sine reference, a second sine reference, and a third sine reference; generate a set of unbalanced current set points based on the product; and regulate the first current of the first current controller, the second current of the second current controller, and the third current of the third current controller using the set of unbalanced current set points.

Abstract: Disclosed solutions relate to electrical inverters. An inverter may further include may include a power module including phase switches, a first negative DC power tab, and a second negative DC power tab. The first negative DC power tab and the second negative DC power tab are connected to one or more of the phase switches. The inverter may further include a positive DC power tab positioned between the first negative DC power tab and the second negative DC power tab and connected to the phase switches. The inverter may further include one or more phase AC power tabs to receive AC power from the phase switches.

Abstract: Disclosed solutions relate to electrical inverters. In an example, a system including an inverter to convert DC power from a voltage source to AC power to drive a winding of a motor is disclosed. The inverter includes a first power module, which includes a first inverter to be connected to a first end of the winding and to be connected to the voltage source. The first inverter is configured to output first AC power to the first end of the winding. The first power module includes a second inverter to be connected to a second end of the winding and to be connected to the voltage source. The second inverter is configured to output second AC power to the second end of the winding. first power module includes a changeover switch to selectively connect and disconnect the second end of the winding to and from a neutral connection.

Abstract: A method includes performing, by one or more controllers, operations including: receiving a pulse to control an operation of a power switch including a gate terminal; generating, based on the received pulse, a first signal to the gate terminal to increase a gate voltage level of the power switch at a first rate from an off-state gate voltage level to a first on-state gate voltage level in a first time period; and generating, based on the received pulse, a second signal to the gate terminal to increase the gate voltage level of the power switch at a second rate, less than the first rate, to a second on-state gate voltage level in a second time period subsequent to the first time period.

Abstract: A system for an electric vehicle includes a power switch configured to convert DC power from a battery to AC power to drive a motor, and a three-dimensionally printed heat sink (3D heat sink) coupled to the power switch.

Abstract: A system includes: an inverter configured to convert DC power from a battery to AC power to drive a motor, wherein the inverter includes: a power switch including a gate terminal; and a gate driver configured to: receive a pulse to control an operation of the power switch, generate, based on the received pulse, a first signal to the gate terminal to increase a gate voltage level of the power switch at a first rate from an off-state gate voltage level to a first on-state gate voltage level in a first time period, and generate, based on the received pulse, a second signal to the gate terminal to increase the gate voltage level of the power switch at a second rate, less than the first rate, to a second on-state gate voltage level in a second time period subsequent to the first time period.

Abstract: A system includes: an inverter configured to convert DC power to AC power, wherein the inverter includes: a power module including: a flex layer including a gate trace providing an electrical connection to a gate input connection of the power module, a first substrate, a second substrate including a source plane, the source plane including a step trench, a semiconductor die disposed between the first substrate and the second substrate, the step trench formed in a portion of the source plane corresponding to at an edge of the semiconductor die, and the semiconductor die including a gate connected to the gate trace, and a sinter element disposed between the semiconductor die and the second substrate to connect the semiconductor die to the second substrate; a battery configured to supply the DC power to the inverter; and a motor configured to receive the AC power from the inverter.

Abstract: A system comprises: an inverter configured to convert DC power from a battery to AC power to drive a motor, wherein the inverter includes: a power module including a drain terminal and a source terminal; one or more phase switches configured to control a current flow between the drain terminal and the source terminal; and a point-of-use controller including two or more thermal sensors on the point-of-use controller, the point-of-use controller configured to determine a temperature of the one or more phase switches using the two or more thermal sensors.

Abstract: A system includes: an alternating current (AC) to direct current (DC) converter (AC-DC converter), the AC-DC converter connectable to a line voltage; and a DC to DC converter (DC-DC converter) connected to the AC-DC converter, the DC-DC converter including: a high voltage buck-boost converter having a secondary side connectable to a high voltage battery; a low voltage buck-boost converter having a secondary side connectable to a low voltage battery; and one or more transformers having a primary side connected to the AC-DC converter, a secondary side connected to a primary side of the high voltage buck-boost converter, and a tertiary side connected to a primary side of the low voltage buck-boost converter.

Abstract: A system includes: a battery charger to convert AC power to DC power to charge a battery, wherein the battery charger includes: an upper switch to condition an input voltage and input current; a lower switch to condition the input voltage and the input current: an upper silicon controlled rectifier (SCR); a lower SCR; and a bulk capacitor.