Abstract: Some embodiments of the invention provide an electric machine module including a housing that defines a machine cavity. A coolant jacket can be at least partially defined by the housing. In some embodiments, a plurality of coolant apertures can be disposed through portions of the housing to fluidly connect the coolant jacket and the machine cavity. One or more solenoid assemblies can be at least partially supported by the housing and positioned substantially adjacent to at least some of the coolant apertures. The solenoid assemblies can be configured to regulate passage of a coolant into the machine cavity from the coolant jacket.

Abstract: Some embodiments of the invention provide an electric machine module including a housing that defines a machine cavity. A coolant jacket can be at least partially defined by the housing. In some embodiments, a plurality of coolant apertures can be disposed through portions of the housing to fluidly connect the coolant jacket and the machine cavity. One or more solenoid assemblies can be at least partially supported by the housing and positioned substantially adjacent to at least some of the coolant apertures. The solenoid assemblies can be configured to regulate passage of a coolant into the machine cavity from the coolant jacket.

Abstract: A method of blocking electro-magnetic interference (EMI) in an electric machine having a housing including an interior portion, an opening leading to the interior portion, and an enclosure positioned about the opening, includes positioning an EMI blocking member in the enclosure across the opening. The EMI blocking member includes an insulating layer having a first surface and a second surface. An EMI shield member is positioned on one of the first and second surfaces. The EMI shield member includes a surface formed from an electrically conductive material that substantially covers the one of the first and second surfaces. The EMI shield member is grounded to the housing. The EMI shield member is configured and disposed to block EMI release from the housing via the enclosure.

Abstract: Embodiments of the invention provide an electric machine module including a housing. The housing can include a machine cavity. In some embodiments, an electric machine can be at least partially positioned within the machine cavity and can include a stator assembly. The stator assembly includes a stator core with slots. In some embodiments, conductors can be positioned in the slots. The conductors include a turn portion extending between leg portions. The leg portions include an angled portion and a connection portion. The conductors are disposed within the plurality of slots so that the angled and connection portions extend from the stator core at a first axial side. At least one insulation member can be disposed over at least some of the leg portions so that the connection portions are at least partially uncovered.

Abstract: Some embodiments of the invention provide an electric machine module comprising an electric machine including a rotor assembly and a rotor hub. In some embodiments, the module can include a output shaft substantially circumscribed by the rotor hub and including at least one channel and at least one coolant outlet. A cavity can be formed by at least the output shaft and the rotor hub. Some embodiments can include a sleeve substantially circumscribing a portion of the output shaft with at least a portion of the sleeve positioned substantially within the cavity between the output shaft and the rotor hub. The sleeve can include at least one groove.

Abstract: Embodiments of the invention provide an electric machine module. The module can include a housing, which can define a machine cavity. In some embodiments, a stator assembly can be positioned within the machine cavity. In some embodiments a transfer member can substantially contact at least a portion of the stator end turns. The transfer member can be in thermal communication with some of the stator end turns and a portion of the housing. In some embodiments, the transfer member can include a substantially non-liquid first element and a substantially liquid second element.

Abstract: An electric machine having insulated conductor wires and a method of insulating the conductor wires. The conductor wires include an electrically conductive core and an electrical insulation portion. The electrical insulation portion includes an electrical insulation coating layer and at least one electrical insulation wrap layer.

Abstract: Some embodiments of the invention provide an electric machine module comprising an electric machine including a rotor assembly and a rotor hub. In some embodiments, the module can include a output shaft substantially circumscribed by the rotor hub and including at least one channel and at least one coolant outlet. A cavity can be formed by at least the output shaft and the rotor hub. Some embodiments can include a sleeve substantially circumscribing a portion of the output shaft with at least a portion of the sleeve positioned substantially within the cavity between the output shaft and the rotor hub. The sleeve can include at least one groove.

Abstract: A method of blocking electro-magnetic interference (EMI) in an electric machine having a housing including an interior portion, an opening leading to the interior portion, and an enclosure positioned about the opening, includes positioning an EMI blocking member in the enclosure across the opening. The EMI blocking member includes an insulating layer having a first surface and a second surface. An EMI shield member is positioned on one of the first and second surfaces. The EMI shield member includes a surface formed from an electrically conductive material that substantially covers the one of the first and second surfaces. The EMI shield member is grounded to the housing. The EMI shield member is configured and disposed to block EMI release from the housing via the enclosure.

Abstract: An ignition apparatus includes a cylindrical core made from magnetically-permeable material and a C-shaped magnetic return path structure that is made from a stack of silicon steel laminations. A tightly controlled air gap is provided between one leg of the C-shaped structure and an end face of the core, forming a magnetic circuit having a high magnetic permeability, which overall reduces the number of primary winding turns needed, thereby reducing the amount of copper wire. In addition, the circular cross-section of the core reduces the mean length per turn (MLT) of the primary winding because the primary winding can be wound directly on the core, which in turn also reduces the MLT of the secondary winding. The reduced MLT also reduces the amount of copper wire. The structure may be replaced using a magnetically-permeable, U-shaped shield.

Abstract: An ignition apparatus includes a transformer having a central core, a primary winding disposed thereabout, a secondary winding disposed outwardly of the primary winding, a case configured to house the central components, and an outer core or shield disposed outwardly of the secondary winding. The central core is formed from multiple, low carbon steel wires held together is a cylindrical shape with cured bond coating material such as an epoxy material or an aromatic polyamide material. In one configuration, at least two different sizes of wires are used in forming the core to increase the density of the magnetically-permeable wire material in the core.

Abstract: An ignition apparatus includes a cylindrical core made from magnetically-permeable material and a C-shaped magnetic return path structure that is made from a stack of silicon steel laminations. A tightly controlled air gap is provided between one leg of the C-shaped structure and an end face of the core, forming a magnetic circuit having a high magnetic permeability, which overall reduces the number of primary winding turns needed, thereby reducing the amount of copper wire. In addition, the circular cross-section of the core reduces the mean length per turn (MLT) of the primary winding because the primary winding can be wound directly on the core, which in turn also reduces the MLT of the secondary winding. The reduced MLT also reduces the amount of copper wire. The structure may be replaced using a magnetically-permeable, U-shaped shield.

Abstract: An ignition apparatus includes a transformer having a central core, a primary winding disposed thereabout, a secondary winding disposed outwardly of the primary winding, a case configured to house the central components, and an outer core or shield disposed outwardly of the secondary winding. The central core is formed from multiple, low carbon steel wires held together is a cylindrical shape with cured bond coating material such as an epoxy material or an aromatic polyamide material. In one configuration, at least two different sizes of wires are used in forming the core to increase the density of the magnetically-permeable wire material in the core.

Abstract: An ignition apparatus includes an oil seal integrated with a spark plug boot and configured to mate with a cylinder head so as to seal the oil that is found under the cam cover from the spark plug and high voltage terminal of the plug. The cylinder head includes a ring-cavity recessed in the head surrounding the spark plug. The spark plug boot includes an annular sealing rib on a lowermost axial end. The sealing rib is configured in size and shape to effect an interference fit in the ring cavity. The ignition apparatus includes another seal integrated at the top to seal to the cam cover. The two integrated seals eliminate the need for a spark plug tube.

Abstract: A twin spark ignition apparatus having two high-voltage (HV) outputs incorporates features for balancing load capacitance on each HV output. The ignition apparatus provides a first high-voltage (HV) connection configured for direct mounting on a first spark plug, and a second HV connection for coupling to a second spark plug by way of an HV cable. The HV cable would adds capacitance at the second HV output, as compared to a direct mount. Various structures are included to offset and balance the additional capacitance attributable to the HV cable so that the capacitance of the first HV connection and the second HV connection are balanced within a range. The voltage variation between the two HV outputs is reduced.