Abstract: An assembly includes a rotor assembly having a rotor stack with an outer rotor diameter and a rotor shaft extending along a rotational axis of the rotor assembly. A mandrel includes an outer mandrel diameter extending between a proximal end and a distal end with a rotor engaging surface at the distal end of mandrel. The outer mandrel diameter includes a first cylindrical portion adjacent the proximal end, a conical portion distal of the first cylindrical portion with a first transitional portion connecting the first cylindrical portion to the conical portion. The assembly also includes a sleeve having an inner sleeve diameter that is less than the outer rotor diameter when in an unexpanded state.

Abstract: A battery system for a motor vehicle or another electrical system includes a battery cover, one or more battery cells, and a diverter assembly. The cells define a battery cavity in fluid communication with a corresponding vent opening. An air gap may be defined in an exhaust volume within the battery system. The diverter assembly includes a diverter body arranged relative to the vent openings. The diverter body is moveable or stationary. In response to a thermal propagation event occurring in the module or at least one of the battery cells, each diverter body diverts a high-temperature flow of ejecta from the cavity into an exhaust volume in a predetermined flow direction when the flow of ejecta passes through the vent opening. The diverter assembly may include a support member connected to the diverter body and connectable to the battery cell.

Abstract: A rotor for a rotary electric machine incudes an annular stack of rotor lamination layers (“rotor lams”) constructed of a magnetic core material. The rotor lams include inner axial surfaces collectively defining a first plurality of openings through the magnetic core material, a second plurality of openings through the magnetic core material, and a third plurality of openings through the magnetic core material. Each respective one of a first plurality permanent magnets, a second plurality of permanent magnets, and a third plurality of permanent magnets, is disposed respectively within a corresponding one of the first plurality of openings, the second plurality of openings, and the third plurality of openings. The first plurality and the third plurality of permanent magnets include high-coercivity magnets. The second plurality of permanent magnets includes low-coercivity magnets.

Abstract: Presented are battery assemblies containing long prismatic cells with interleaved gas manifolds and electrical busbars, methods for making/using such battery assemblies, and vehicles equipped with such battery assemblies. A prismatic battery assembly includes multiple stacks of prismatic battery cells that are located inside of and extend longitudinally across a rigid and insulated assembly housing. Each battery cell includes a prism-shaped cell can that contains one or more electrochemical cells. Located at one or both lateral ends of each cell can are a cell vent and a pair of electrical terminals. Electrically connected to the battery cell terminals is an electrical busbar that is located inside the assembly housing, either between the cell stacks or laterally outboard of the cell stacks. Fluidly connected to the battery cell vents is a gas manifold that is located inside the assembly housing, either between the cell stacks or laterally outboard of the cell stacks.

Abstract: A magnet-free electric machine. The electric machine may include a stator including a first stator winding set and a second stator winding set and a rotor including a first rotor winding set and a second rotor winding set. The electric machine may include a power transfer circuit configured for controlling a polarity and/or a phase sequence of excitation currents used in exciting the first and second stator and rotor windings, and thereby, respectively generated stator and rotor poles.

Abstract: The present disclosure describes a multi-function, integrated Super Beam assembly structure with integrated structural, cooling, and transverse elastic compliance functions; and Thermal Management Propagation (TMP) protection. The Super Beam assembly includes a pair of parallel face plates, coolant channel cover plates, and coolant channels that are defined by the face plate and the one or more coolant channel cover plates. The structural design of the cooling channels, and the corresponding air gaps formed in-between them, allows a transverse elastic compliance of the Super Beam assembly to be tuned to different amounts of elasticity. Top, bottom and/or end structural channels may be included. A pair of TMP suppression channels may be attached to the Super Beam assembly structure with an adhesive “thermal fuse” that preferentially melts and causes the pair of TMP suppression channels to detach from the Super Beam assembly during overheating in a TMP event.

Abstract: A modular multi-cell rechargeable energy storage system (RESS) includes a RESS enclosure surrounded by an external environment and having an enclosure tray, an enclosure cover, and a rail structure. The RESS also includes a plurality of mechanically interconnected battery cell blocks arranged in the RESS enclosure. Each battery cell block includes a cell case having at least one interface connector configured to couple the cell case to the rail structure, such that each battery cell block is engaged with and aligned and supported by the rail structure.

Abstract: A battery pack includes a first header having a first conduit and a second header having a second conduit. The battery pack also includes an energy storage system having energy storage cells arranged between the first header and the second header. A coolant plate assembly is arranged between the first header and the second header and abuts the plurality of energy storage cells. The coolant plate assembly includes a coolant channel having a first end fluidically connected to the first conduit, a second end fluidically connected to the second conduit, and an intermediate portion defining a flow path. The coolant plate assembly also includes a first planar section having a first surface facing the energy storage cells and a second surface having protrusions extending into the coolant channel.

Abstract: A modular multi-cell rechargeable energy storage system (RESS) includes a RESS enclosure surrounded by an external environment and having an enclosure tray and an enclosure cover. The RESS also includes a plurality of battery cell blocks arranged in the RESS enclosure. Each battery cell block includes a cell case including a cell vent and at least one electrically insulated structural connector configured to link the cell case with an adjacent battery cell block. Each battery cell block also includes a thermal mitigation barrier (TMB) segment fixed to the cell case and configured to contact the adjacent battery cell block. Each battery cell block additionally includes a thermal insulator configured to line the cell vent. Furthermore, each battery cell block includes a bus bar segment configured to interconnect with a bus bar segment of the adjacent battery cell block.

Abstract: A heat transfer system includes first and second battery cells, a heat sink, and a plurality of sheets of a thermally conductive material arranged in a stack. The first and second battery cells are arranged adjacent to each other. The heat sink is arranged adjacent to the first and second battery cells. A first portion of the stack is disposed between the first and second battery cells. A second portion of the stack is disposed adjacent to and in thermal communication with the heat sink. The first portion of the stack conducts heat from the first battery cell while limiting heat conducted to the second battery cell. The second portion of the stack transfers the heat to the heat sink.

Abstract: Rotor for electric machines and methods for fabricating rotors for electric machines are provided. An exemplary method includes assembling a stack of laminations to form a rotor core having an external surface. The rotor core defines one to five layers of internal cavities and an interior permanent magnet is positioned in a selected internal cavity. The method also includes locating a non-magnetic structural element in the selected internal cavity. Further, the method includes applying a compressive force on the external surface of the rotor core with an annular sleeve.

Abstract: A synchronous machine having a hybrid rotor excitation. The synchronous machine includes a rotor having a plurality of permanent magnets and electromagnets embedded within a rotor body. The permanent magnets produces a constant magnet field having a magnetic axis along a direct axis (D-axis). The electromagnets produces a variable magnetic field along a magnetic axis offset from the D-axis, preferable substantially orthogonal to the D-axis. The plurality of permanent magnets are separated from the electromagnets by a rotor air-gap. The plurality of permanent magnets includes inner pairs and outer pairs of permanent magnets nested in a V-shaped configuration. In another embodiment, the outer pairs of permanent magnets are replaced with outer radius electromagnets.

Abstract: Presented are clutch-type engine disconnect devices, methods for making/using such disconnect devices, and motor vehicles equipped with such disconnect devices. An engine disconnect device includes a notch plate, which has multiple notches and attaches to a torque converter, and a pocket plate, which has multiple pockets and attaches to an engine's crankshaft. A pawl is movably mounted within each notch; these pawls selectively engage the notches with the pockets. A notch plate insert is nested within each notch, supporting thereon one of the pawls. A selector plate interposed between the pocket and notch plates moves from a first position, to shift the pawls out of engagement with the pockets, and a second position, to move the notch plate inserts within the notches and allow the pawls to engage the notches with the pockets to thereby lock the notch plate to the pocket plate to rotate in unison with each other.

Abstract: A heat transfer system includes first and second battery cells, a heat sink, and a plurality of sheets of a thermally conductive material arranged in a stack. The first and second battery cells are arranged adjacent to each other. The heat sink is arranged adjacent to the first and second battery cells. A first portion of the stack is disposed between the first and second battery cells. A second portion of the stack is disposed adjacent to and in thermal communication with the heat sink. The first portion of the stack conducts heat from the first battery cell while limiting heat conducted to the second battery cell. The second portion of the stack transfers the heat to the heat sink.

Abstract: A rotor core for an electric machine of an automobile includes a core stack including a plurality of lamination plates, each lamination plate including a plurality of apertures formed therein, the apertures of each of the lamination plates axially aligned to define a plurality of magnet slots extending axially through the core stack, a plurality of magnets stacked axially within each of the plurality of magnet slots along a length of the core stack, at least one of the plurality of magnet slots including a cavity extending axially along the length of the core stack, and a wedge inserted within the cavity adapted to apply a lateral force onto the plurality of magnets within the at least one magnet slot to secure the plurality of magnets within the at least one magnet slot.

Abstract: Rotor for electric machines and methods for fabricating rotors for electric machines are provided. An exemplary method includes assembling a stack of laminations to form a rotor core having an external surface. The rotor core defines one to five layers of internal cavities and an interior permanent magnet is positioned in a selected internal cavity. The method also includes locating a non-magnetic structural element in the selected internal cavity. Further, the method includes applying a compressive force on the external surface of the rotor core with an annular sleeve.

Abstract: A method for constructing a rotor assembly for use with a rotary electric machine includes forming annular rotor laminations from metal blanks. Each lamination has a radial axis and an outer diameter surface. Multiple magnet web regions are defined in proximity to the outer diameter surface. Each web regions includes asymmetrical openings defined by a radially-extending strut and arcuate peripheral bridges. The method includes coaxially stacking the laminations into a rotor stack, including positioning every other lamination a predetermined angular distance with to unmask the bridges and/or struts and mask remaining surface area of the laminations. The rotor stack is subjected to a heat-treating process to harden only the unmasked bridges and/or struts. The method includes connecting a rotor shaft to the stack to construct the rotor assembly, with the web regions corresponding to a respective rotor magnetic pole.

Abstract: A rotor core for an electric motor includes a core stack including a plurality of lamination plates, each lamination plate including a plurality of apertures formed therein, the plurality of apertures of each of the lamination plates axially aligned and defining a plurality of axial magnet slots extending through the core stack and adapted to support a plurality of permanent magnets therein, and at least one insert extending axially through the core stack and adapted to provide radial structural stability to the plurality of lamination plates to prevent portions of the plurality of lamination plates adjacent the plurality of magnet slots from flexing due to radial forces exerted on the plurality of lamination plates during operation of the electric motor.

Abstract: A rotor core for an electric machine of an automobile includes a core stack including a plurality of lamination plates, each lamination plate including a plurality of apertures formed therein, the apertures of each of the lamination plates axially aligned to define a plurality of magnet slots extending axially through the core stack, a plurality of magnets stacked axially within each of the plurality of magnet slots along a length of the core stack, at least one of the plurality of magnet slots including a cavity extending axially along the length of the core stack, and a wedge inserted within the cavity adapted to apply a lateral force onto the plurality of magnets within the at least one magnet slot to secure the plurality of magnets within the at least one magnet slot.

Abstract: A rotary electric machine for use with coolant includes a stator and rotor assembly. The rotor assembly includes a rotor, rotor shaft, and first and second end rings. The rotor has inner and outer diameter surfaces and an embedded set of rotor magnets proximate the outer diameter surface. The shaft is connected to the rotor and defines a main coolant passage along an axis of rotation. Radial shaft coolant passages are in fluid communication with the main coolant passage. The end rings are positioned at opposing distal ends of the rotor. The shaft coolant passages direct the coolant into the rotor and/or the end rings such that the coolant flows axially through rotor cavities of the rotor and cools the rotor magnets via forced convection.