Abstract: A stator includes a stator hub, a plurality of stator teeth extending from stator hub that define a stator slot and at least one winding disposed in the stator slot, the winding including a cooling passage formed therein through. The cooling passage is connected to an inlet plenum and an outlet plenum. The stator can also include coil separators tint include cooling passages.

Abstract: A header for an electric machine that include a stator core and one or more windings that include coolant passages formed therein. The header includes an inlet to receive a coolant, an outlet though which the coolant exits the header, an inlet plenum fluidly connected to the inlet, and an outlet plenum fluidly separated from the inlet plenum and fluidly connected to the outlet. The inlet and outlet plenums each have a varying cross section that varies from a top of the header as compared to a bottom of the header.

Abstract: Electric motors and stators thereof are described. The stators of the electric motors include a first header, a second header fluidly connected to the first header, a plurality of windings fluidly connected to the first header and the second header to receive a cooling fluid passing from the first header to the second header along one or more flow channels, and one or more phase-change material elements arranged to thermally interact with at least one of the first header, the second header, the one or more flow channels, and the plurality of windings.

Abstract: Aircraft electric motors are described. The aircraft electric motors include a cooling system comprising an annular heat exchanger, a motor housing arranged radially inward from the heat exchanger, the motor housing defining a rotor-stator cavity and a gear assembly cavity, a rotor sleeve arranged within the rotor-stator cavity, a gear assembly arranged within the gear assembly cavity, a first shaft operably coupled to the rotor sleeve and configured to be rotationally driven by the rotor sleeve to drive rotation of a portion of the gear assembly, and a second shaft operably coupled to the gear assembly and configured to be rotationally driven by the gear assembly.

Abstract: An electric motor system includes an electric motor, and a thermal management system. The thermal management system includes a two-phase refrigerant circuit circulating a flow of refrigerant through the electric motor, and a refrigerant-air heat exchanger fluidly connected to the electric motor via the two-phase refrigerant circuit, such that the flow of refrigerant is boiled via heat generated by the electric motor, and returned to a subcooled liquid state to cool the electric motor. A method of dissipating thermal energy from an electric motor includes urging a flow of refrigerant through an electric motor, thereby boiling the flow of refrigerant, directing the flow of refrigerant from the electric motor to a refrigerant-air heat exchanger via a two-phase refrigerant circuit, and cooling the refrigerant to a sub-cooled liquid state at the refrigerant-air heat exchanger via thermal energy exchange with a flow of air through the refrigerant-air heat exchanger.

Abstract: A motor drive architecture is provided. The motor drive architecture includes a three-dimensional (3D) stack of cold plates on which power electronic components for an electric machine are mountable and supporting structures. Each cold plate has an annular shape with internal fluid pathways. The supporting structures hold the cold plates in the 3D stack. At least one supporting structure defines an internal cavity bifurcated into an internal inlet fluid pathway configured to direct fluid into the internal fluid pathways of each cold plate and an internal outlet fluid pathway receptive of the fluid from the internal fluid pathways of each cold plate.

Abstract: An electronics assembly includes a motor controller electronics arrangement with a solid-state switch array, a feeder cable connected to the motor controller and in electrical communication with the solid-state switch array, and a phase change material body. The phase change material body is thermally coupled to the feeder cable and arranged outside of the motor controller to limit conduction of heat generated by resistive heating of the feeder cable into the motor controller and through the feeder cable. Vehicles, electrical systems, and methods of cooling feeder cables in motor controller electronics arrangements are also described.

Abstract: A stator includes a stator hub and a plurality of stator teeth extending from the stator hub that define a stator slot having a stator slot base. At least one winding is disposed in the stator slot and the stator also includes a back iron. The winding surrounds the back iron and is held apart from the stator slot base so that a fluid channel is defined between an inner winding portion of the at least one winding so fluid can be passed between the stator slot base and the inner winding portion to cool the inner winding portion.

Abstract: Disclosed is an assembly including a busbar that includes: a first layer that defines: first layer top and bottom surfaces; first layer first and second ends; and a first layer center region between the first layer first and second ends; and the first layer forms first layer perforations of different sizes about the first layer center region so perforations closer to the first layer first end are smaller than perforations spaced apart therefrom; a second layer that is disposed against and electrically isolated from the first layer bottom surface, wherein the second layer defines connector orifices having a same size as each other that are aligned with the first layer perforations; and a first capacitor supported against and electrically connected to the first layer top surface, wherein the first capacitor includes busbar connectors that respectively extend through the first layer perforations to electrically connect with the connector orifices.

Abstract: Disclosed is a heat transfer system with a module that includes a peripheral frame (10) and an electrocaloric element (46) disposed in an opening in the peripheral frame. The electrocaloric element includes an electrocaloric film (46), a first electrode (48) on a first side of the electrocaloric film, and a second electrode (50) on a second side of the electrocaloric film. First and second electrically conductive elements (24, 25) are disposed adjacent to first and second surfaces of the peripheral frame, and provide an electrical connection to the first and second electrodes.

Abstract: A stator includes a stator hub and a plurality of stator teeth extending from the stator hub that define a stator slot having a stator slot base. At least one winding is disposed in the stator slot and the stator also includes a back iron. The winding surrounds the back iron and is held apart from the stator slot base so that a fluid channel is defined between an inner winding portion of the at least one winding so fluid can be passed between the stator slot base and the inner winding portion to cool the inner winding portion.

Abstract: Aircraft electric motors are described. The aircraft electric motors include a cooling system comprising an annular heat exchanger, a motor housing arranged radially inward from the heat exchanger, the motor housing defining a rotor-stator cavity and a gear assembly cavity, a rotor sleeve arranged within the rotor-stator cavity, a gear assembly arranged within the gear assembly cavity, a first shaft operably coupled to the rotor sleeve and configured to be rotationally driven by the rotor sleeve to drive rotation of a portion of the gear assembly, and a second shaft operably coupled to the gear assembly and configured to be rotationally driven by the gear assembly.

Abstract: A motor drive architecture is provided. The motor drive architecture includes a three-dimensional (3D) stack of cold plates on which power electronic components for an electric machine are mountable and supporting structures. Each cold plate has an annular shape with internal fluid pathways. The supporting structures hold the cold plates in the 3D stack. At least one supporting structure defines an internal cavity bifurcated into an internal inlet fluid pathway configured to direct fluid into the internal fluid pathways of each cold plate and an internal outlet fluid pathway receptive of the fluid from the internal fluid pathways of each cold plate.

Abstract: An electric motor system includes an electric motor, and a thermal management system. The thermal management system includes a two-phase refrigerant circuit circulating a flow of refrigerant through the electric motor, and a refrigerant-air heat exchanger fluidly connected to the electric motor via the two-phase refrigerant circuit, such that the flow of refrigerant is boiled via heat generated by the electric motor, and returned to a subcooled liquid state to cool the electric motor. A method of dissipating thermal energy from an electric motor includes urging a flow of refrigerant through an electric motor, thereby boiling the flow of refrigerant, directing the flow of refrigerant from the electric motor to a refrigerant-air heat exchanger via a two-phase refrigerant circuit, and cooling the refrigerant to a sub-cooled liquid state at the refrigerant-air heat exchanger via thermal energy exchange with a flow of air through the refrigerant-air heat exchanger.

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: Disclosed is an assembly including a busbar that includes: a first layer that defines: first layer top and bottom surfaces; first layer first and second ends; and a first layer center region between the first layer first and second ends; and the first layer forms first layer perforations of different sizes about the first layer center region so perforations closer to the first layer first end are smaller than perforations spaced apart therefrom; a second layer that is disposed against and electrically isolated from the first layer bottom surface, wherein the second layer defines connector orifices having a same size as each other that are aligned with the first layer perforations; and a first capacitor supported against and electrically connected to the first layer top surface, wherein the first capacitor includes busbar connectors that respectively extend through the first layer perforations to electrically connect with the connector orifices.

Abstract: An electronics assembly includes a motor controller electronics arrangement with a solid-state switch array, a feeder cable connected to the motor controller and in electrical communication with the solid-state switch array, and a phase change material body. The phase change material body is thermally coupled to the feeder cable and arranged outside of the motor controller to limit conduction of heat generated by resistive heating of the feeder cable into the motor controller and through the feeder cable. Vehicles, electrical systems, and methods of cooling feeder cables in motor controller electronics arrangements are also described.

Abstract: A heat transfer system includes first (62) and second (64) electrocaloric module with aligned first and second sides. First and second prime movers (80,82) are arranged to direct a working fluid in opposite directions along flow paths through the electrocaloric modules. A rotary fluid control device (92,98) including a plurality of openings (94,96,100,102) is disposed around the electrocaloric modules, and is configured to rotate between positions relative to the modules. In a first position, the first module is in operative fluid communication through the openings with the first prime mover, and the second module is in operative fluid communication through the openings with the second prime mover. In a second position, the first module is in operative fluid communication through the openings with the second prime mover, and the second module is in operative fluid communication through the openings with the first prime mover.

Abstract: A cooling system includes an electrocaloric element having a nanoparticulate ion scavenger and a co-continuous polymer network of a first polymer phase and a second polymer phase wherein the first polymer includes a liquid crystal polymer. A pair of electrodes is disposed on opposite surfaces of the electrocaloric element. A first thermal flow path is disposed between the electrocaloric element and a heat sink. A second thermal flow path is disposed between the electrocaloric element and a heat source. The system also includes a controller configured to control electrical current to the electrodes and to selectively direct transfer of heat energy from the electrocaloric element to the heat sink along the first thermal flow path or from the heat source to the electrocaloric element along the second thermal flow path.

Abstract: Disclosed is a heat transfer system with a module that includes a peripheral frame (10) and an electrocaloric element (46) disposed in an opening in the peripheral frame. The electrocaloric element includes an electrocaloric film (46), a first electrode (48) on a first side of the electrocaloric film, and a second electrode (50) on a second side of the electrocaloric film. First and second electrically conductive elements (24, 25) are disposed adjacent to first and second surfaces of the peripheral frame, and provide an electrical connection to the first and second electrodes.