Abstract: A vehicle power module assembly including first and second power modules is provided. The first power module may include a first lock feature extending from a lower portion of a first minor side at a first central axis. The second power module may include a second lock feature at an upper portion of a second minor side at a second central axis. The lock features may be sized for interlock with one another to secure the power modules to one another. The first lock feature may be a loop element defining a through-hole and the second lock feature may be a wedge. The through-hole may be sized for the wedge to extend therein and to interlock the first power module and the second power module to one another. The first lock feature may be a flexible hook element and the second lock feature may be a slot.

Abstract: A rotor for an electric machine includes pairs of magnets with a bridge region therebetween. Lamination that comprise the rotor may define openings in the bridge region between the magnets of each of the pairs. A clip may be installed in the openings and a bonding material may fill the remainder of the bridge region.

Abstract: An electric machine includes a plurality of planar laminations stacked to form an electrical steel rotor having openings defining magnet pockets and adjacent inner side pockets. The adjacent inner side pockets define a center bridge therebetween and have blasted surface portions such that compressive stress layers are induced along edges of the center bridge to strengthen the center bridge.

Abstract: A vehicle power module assembly including first and second power modules is provided. The first power module may include a first lock feature extending from a lower portion of a first minor side at a first central axis. The second power module may include a second lock feature at an upper portion of a second minor side at a second central axis. The lock features may be sized for interlock with one another to secure the power modules to one another. The first lock feature may be a loop element defining a through-hole and the second lock feature may be a wedge. The through-hole may be sized for the wedge to extend therein and to interlock the first power module and the second power module to one another. The first lock feature may be a flexible hook element and the second lock feature may be a slot.

Abstract: A vehicle power module assembly including first and second power modules is provided. The first power module may include a first lock feature extending from a lower portion of a first minor side at a first central axis. The second power module may include a second lock feature at an upper portion of a second minor side at a second central axis. The lock features may be sized for interlock with one another to secure the power modules to one another. The first lock feature may be a loop element defining a through-hole and the second lock feature may be a wedge. The through-hole may be sized for the wedge to extend therein and to interlock the first power module and the second power module to one another. The first lock feature may be a flexible hook element and the second lock feature may be a slot.

Abstract: A rotor for an electric machine includes pairs of magnets with a bridge region therebetween. Lamination that comprise the rotor may define openings in the bridge region between the magnets of each of the pairs. A clip may be installed in the openings and a bonding material may fill the remainder of the bridge region.

Abstract: A rotor for an electric machine includes pairs of magnets with a bridge region therebetween. Lamination that comprise the rotor may define openings in the bridge region between the magnets of each of the pairs. A clip may be installed in the openings and a bonding material may fill the remainder of the bridge region.

Abstract: An electric vehicle power supply includes a housing, a power supply, and a plurality of fasteners. The housing defines an internal cavity and has inwardly protruding tabs that extend into the cavity. The power assembly has a front cover and an end cover. The power assembly also has an array of electrical switching units arranged horizontally between the front and end covers. The front and end covers have outwardly protruding tabs. Each of the plurality of fasteners extend vertically, engage one inwardly protruding tab, and engage one outwardly protruding tab to secure the power assembly to the housing.

Abstract: A method of forming a power-module assembly includes arranging power stages in a cavity of a container such that the power stages are spaced apart from walls of the container. The method further includes inserting a core between each of the power stages, and installing a manifold on top of the power stages. The method also includes putting resin into the cavity to form a housing of the power-module assembly, and removing the core to reveal coolant chambers between each of the power stages.

Abstract: An automotive motor includes a stator and a rotor disposed within the stator. The automotive motor also includes an endplate attached to the rotor that defines a coolant exit hole, an outer edge, and an array of staggered raised flow disruptors disposed radially between the coolant exit hole and outer edge. The array disrupts flow of coolant as the coolant travels from the coolant exit hole along a surface of the endplate toward the outer edge.

Abstract: An electric machine includes a plurality of planar laminations stacked to form an electrical steel rotor having openings defining magnet pockets and adjacent inner side pockets. The adjacent inner side pockets define a center bridge therebetween and have blasted surface portions such that compressive stress layers are induced along edges of the center bridge to strengthen the center bridge.

Abstract: An electric machine configured to propel a vehicle includes a stator, a rotor, and an end plate. The stator has end windings that protrude axially therefrom. The rotor is disposed within the stator. The end plate is secured to an axial end of the rotor. The end plate defines a primary chamber, a secondary chamber that is radially outward of the primary chamber, and a first outlet channel that is configured to direct fluid onto the end windings. The primary chamber is in fluid communication with a fluid source and the secondary chamber. The secondary chamber is in fluid communication with the outlet channel.

Abstract: An electric machine includes an electrical steel rotor having openings defining magnet pockets and outer side pockets, and having spaced apart axial stripes of increased compressive residual stress layers around a perimeter thereof. The outer side pockets and the perimeter form top bridges therebetween. Each of the axial stripes is aligned with one of the top bridges to strengthen outer edges of the top bridges.

Abstract: An electric machine configured to propel a vehicle includes a stator, a rotor, and an end plate. The stator has end windings that protrude axially therefrom. The rotor is disposed within the stator. The end plate is secured to an axial end of the rotor. The end plate defines a primary chamber, a secondary chamber that is radially outward of the primary chamber, and a first outlet channel that is configured to direct fluid onto the end windings. The primary chamber is in fluid communication with a fluid source and the secondary chamber. The secondary chamber is in fluid communication with the outlet channel.

Abstract: A power-module assembly includes a plurality of power modules each including a power stage having a substrate and a transistor-based switching arrangement supported on the substrate. The power modules are arranged in a stack that defines coolant chambers interleaved with the power stages and defines a pair of coolant-supply manifolds disposed on opposing sides of the stack and extending along a length of the stack. For each power module, the substrate defines a network of cooling channels connecting the supply manifolds to a corresponding one of the chambers. The network includes first channels each configured to receive coolant from the pair of coolant-supply manifolds, second channels substantially parallel to the first channels and each opening into the corresponding one of the chambers, and third channels crisscrossing the first and second channels to connect the first and second channels in fluid communication.

Abstract: A rotor for an electric machine includes pairs of magnets with a bridge region therebetween. Lamination that comprise the rotor may define openings in the bridge region between the magnets of each of the pairs. A clip may be installed in the openings and a bonding material may fill the remainder of the bridge region.

Abstract: A vehicle system is disclosed. The vehicle system includes an automatic transmission fluid cooling conduit. The automatic transmission fluid cooling conduit includes an inlet portion, an outlet portion, and an elbow portion connecting the inlet and outlet portions and having an inner surface defining a cavity in fluid communication with the inlet and outlet portions. The automatic transmission fluid cooling conduit also includes an oleophobic or hydrophobic coating on the inner surface. The oleophobic or hydrophobic coating is configured to reduce eddy currents in the cavity.

Abstract: A power inductor assembly including a power inductor, a vehicle component, and a pair of distribution conduits is provided. The power inductor has a housing supporting a pair of coils. The vehicle component is located above the pair of coils. Each of the pair of distribution conduits is oriented relative to one of the pair of coils below the vehicle component and has one or more openings adjacent the coils to distribute coolant thereto. Each of the one or more openings may define one of a circular shape or a slot shape. Each of the one or more openings may be sized such that exiting coolant substantially uniformly covers the adjacent coil.

Abstract: An electric machine is disclosed. The electric machine includes a stator core defining a cavity and having end-windings protruding from the cavity, and a rotor configured to rotate within the cavity and having end plates defining a plurality of holes for providing coolant. The electric machine also includes one or more layers of an oleophobic or hydrophobic coating disposed on portions of the end plate corresponding to the holes to increase coolant flow to the end-windings.

Abstract: Electronic devices are disclosed including hydrophobic or oleophobic coatings that control coolant flow therein or thereon. In at least one embodiment, a power inverter cold plate is provided including coolant inlet, a coolant outlet, a coolant flow spreading region, a coolant flow collection region, and a coolant heat-transfer region disposed therebetween; and one or more layers of a hydrophobic or oleophobic coating configured to control a flow of coolant in the cold plate. A method may include applying one or more layers of a hydrophobic or oleophobic coating to a power inverter cold plate to control a flow of coolant in the cold plate, the one or more layers being applied to one or more of a coolant flow spreading region, a coolant flow collection region, or a coolant heat-transfer region disposed therebetween. The layers may define coolant flow paths, eliminate recirculation zones, and/or prevent coolant leak paths.