Abstract: Embodiments are directed to obtaining a specification of at least one operational requirement for at least one capacitor, generating a design of the at least one capacitor to satisfy the at least one operational requirement, the design of the at least one capacitor comprising a plurality of layers and a first integrated busbar coupled to at least a portion of the layers, and based on the design, manufacturing the at least one capacitor by utilizing an additive manufacturing technique.

Abstract: An electrical machine includes a winding core with a plurality of end slots. A winding is seated in the end slots with end windings where the winding crosses from end slot to end slot. A slot insulator is seated in two of the end slots. The slot insulator includes a first slot liner seated in a first one of the two end slots with a winding slot defined therethrough in an axial direction. A second slot liner is seated in a second one of the two end slots with a winding slot defined therethrough in the axial direction, wherein the second slot liner is spaced apart in a lateral direction relative to the axial direction from the first slot liner by a gap. The slot insulator includes a span portion bridging across the gap to connect the first and second slot liners.

Abstract: An assembly includes a first conductor, a tube extending along the first conductor between first and second ends of the first conductor, and an electrically-insulating barrier surrounding the first conductor and the tube such that the tube is spaced from the first conductor. Another assembly includes a plurality of conductors, a first tube extending along at least one of the conductors, and an electrically-insulating barrier enclosing the conductors and the first tube in which the barrier maintains spacing between the first tube and one or more adjacent conductors. In each assembly, the tube is configured to permit a fluid to flow therethrough. A method of manufacturing a feeder cable includes providing conductors that extend between first and second lugs of each conductor, enclosing the conductors within an electrically-insulating layer, and forming a cooling passage within the electrically-insulating layer that extends along one of the conductors.

Abstract: An aircraft power distribution system according to an exemplary aspect of the present disclosure includes, among other things, a power source, a load, and a power distribution panel receiving power from the power source and selectively providing power to the load. The power distribution panel includes a contactor having a housing. A heat sink provides a portion of the housing.

Abstract: An aircraft power distribution system according to an exemplary aspect of the present disclosure includes, among other things, a power source, a load, and a power distribution panel receiving power from the power source and selectively providing power to the load. The power source is connected to the power panel by a lug having a heat sink portion. The heat sink portion has at least one increased dimension relative to the remainder of the lug.

Abstract: A contactor interconnect includes a lead post, a bus bar post and a plurality of electrically conductive heat rejection components. The lead post electrically connects to the bus bar post in series through the plurality of heat rejection components. The heat rejection components in turn connect electrically in parallel with one another between the lead post and the bus bar post for conducting current between the posts and passively dissipating heat conveyed from the lead post toward the bus bar post.

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: A motor controller is provided including a motor controller housing an air inlet and an air outlet. A plurality of heat generating elements is disposed within the motor control housing. A cooling system includes a cooling device having a fluid sealed therein arranged within the motor control housing. The plurality of heat generating elements is cooled by conduction to the cooling device and by convection from an air flow between the air inlet and the air outlet.

Abstract: A plurality of cores are arranged in a loop between an inner wall and an outer wall. A gap filler is arranged circumferentially between each of the plurality of cores. A high thermal conductivity potting material is arranged around both the inner and outer edges of the core segments. A winding wraps around each of the plurality of core segments. The windings may be embedded within the high thermal conductivity potting material.

Abstract: Embodiments of an end winding support and heat sink for a pole of a generator are provided. An aspect includes a flat plate portion, the flat plate portion comprising an internal cooling liquid channel that routes coolant through the flat plate portion. Another aspect includes a plurality of fins extending out from the flat plate portion, wherein wires of the windings of the generator are supported by the plurality of fins.

Abstract: A method of manufacturing a nonconductive liquid cooled back iron heat exchanger to house a conductive cooling liquid is disclosed. This method may include forming layers of material via additive manufacturing to create channels for transporting cooling liquid. The layers may be staggered to create electrically insulated liquid cooling channels. This method may include providing cooling liquid from a power electronics cooling system (PECS) heat exchanger via a pressure drop between the PECS heat exchanger back iron heat exchanger. Also described herein is a liquid cooled stator cooling system, including an aircraft cabin air compressor motor. The motor may include a motor housing and a stator core. A liquid cooled back iron heat exchanger may be positioned between the motor housing and the stator core.

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: An integrated circuit assembly element formed via an additive manufacturing technique, such as mixing a conductive material with a memory metal to form a portion of a substrate in desired locations, such as along the footprint of die, are discussed herein. In operation (e.g. in response to thermal cycling of the assembly) the memory metal contracts while the conductive material expands. The result is an element having reduced thermal expansion, which can be net zero coefficient of thermal expansion and/or be catered to the coefficient of thermal expansion of a desired material, such as the silicon die.

Abstract: A fully enclosed fan motor assembly includes a motor housing. A stator is located radially inward from the motor housing. A rotor is located radially inward from the stator, and the gap in between the rotor and stator defines a rotor stator gap. A shaft is located radially inward from the rotor. A fin portion extending radially outward from the shaft is used to dissipate heat from the rotor to air drawn through the rotor stator gap and over the fin portion.

Abstract: An electrical contactor assembly is provided including an electrical bus bar and at least one electrical contactor. The electrical bus bar includes a layer of insulation, a layer of copper, and a composite core having at least one wire embedded therein. The wire is configured to locally reduce thermal strain. The at least one electrical contactor is mounted to the layer of copper through an opening in the layer of insulation. The electrical contactor and the bus bar are thermally and electrically connected.

Abstract: A ram fan device includes a motor disposed in a housing that defines a motor cavity with a fan operatively connected to be driven by the motor and an outlet in fluid communication with the motor cavity. The housing includes a cooling inlet therethrough downstream of the fan and upstream of the motor, the cooling inlet being in fluid communication with the outlet through the motor cavity such that airflow can pass through the cooling inlet through the motor cavity and out the outlet.

Abstract: A controller according to an exemplary aspect of the present disclosure includes, among other things, a cold plate and at least one electronic component mounted to the cold plate by an intermediate thermoelectric cooler.

Abstract: A mist cooling system that includes a casing and a liquid inlet. The casing is configured to receive a liquid flow from a source through the liquid inlet and then provide the liquid flow as a mist to a housing of a motor so as to increase a cooling of the motor and prevent any failure of the motor due to overheating.

Abstract: An inductor assembly includes an inductor core, a winding, and a coolant conduit. The inductor core defines a cavity and the winding is disposed about the inductor core such that a portion of the winding is disposed within the cavity. The coolant conduit extends from a first end of the cavity towards an opposed second end of the cavity and includes an inlet port and an outlet port in fluid communication with each other through the coolant conduit.

Abstract: A liquid cooled generator is provided having a rotor having a central core and a main stator winding wrapped around the central core. A first laminate at a first end of the central core is provided having a first orifice defining a first diameter and a second laminate at a second end of the central core is provided having a second orifice defining a second diameter that is the same as the first diameter. A flow line passes through the central core and is configured to extend from the first laminate to the second laminate, the flow line defining a third diameter that is larger than the first and second diameters. The first and second diameters are configured such that air flow is permitted to pass through the first and second laminates and to restrict the flow of a liquid through the first and second laminates.