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: A cover for a housing of an electric machine is provided. The cover may include an inner sidewall and an outer sidewall. The outer sidewall may be spaced apart from the inner sidewall to define a coolant channel therebetween. The inner sidewall and outer sidewall may be defined by an interior surface of the cover such that the coolant channel receives end windings of a stator of the electric machine when the cover is secured to the housing. The interior surface of the cover may define features between the sidewalls to promote turbulence of coolant flowing through the coolant channel. The interior surface of the cover may define a meandering trough between the sidewalls to form a predetermined coolant path relative to a location of the end windings when the cover is secured to the housing.

Abstract: A power electronics assembly includes a case and an array of power stages disposed within the case. Each of the power stages includes a transistor-based switching arrangement configured to change direct current from a traction battery to alternating current for an electric machine. The power stages are bonded together via a resin to form a monolithic power module adhered to a wall of the case. This disclosure also discloses methods for forming power electronic assemblies.

Abstract: A vehicle power module assembly is provided. The assembly may include a first frame, a second frame, and power stages. The first frame may define a first pair of coolant cavities. The second frame may define a second pair of coolant cavities in communication with the first pair of cavities to define a serial coolant path. Each of the frames may house one of the power stages disposed between the respective pairs of cavities such that coolant flowing through the cavities is in thermal communication with the power stages. The assembly may further include a pair of endplates, one of which defines a channel to divert coolant from a last of the pair of coolant cavities to the outlet cutouts in substantial registration with one another. Each of the first frame and second frame may further define a pass-through fluidly connecting the pair of coolant cavities.

Abstract: An electronic device for an electric powertrain of a vehicle is disclosed. The device includes a power module assembly having a housing that defines a first side, and an array of power modules disposed within the housing. Each of the power modules includes first electrical contact patches at least partially embedded in the first side and having an attachment surface substantially parallel to the first side. A capacitor assembly includes a housing defining a second side that is substantially coplanar with the first side, and an array of second electrical contact patches at least partially embedded in the second side. The second electrical contact patches have an attachment surface substantially parallel to the second side. A busbar mechanically and electrically couples at least one of the first contact patches to at least one of the second contact patches.

Abstract: A power inverter includes a plurality of power modules that each have a frame defining a cavity, and a power stage disposed within the cavity. Each of the frames have a pair of engaging surfaces. The frames are arranged in a stack such that the engaging surfaces adjacent to each other abut. A plurality of seals are interleaved with the modules such that each of the seals is disposed between engaging surfaces of the frames abutting each other.

Abstract: A power-electronics assembly includes a plurality of power modules each having a body, a power stage disposed in the body and having opposing major sides, and a coolant channel defined in the body at a location adjacent to one of the major sides. The modules are arranged in a stack such that the coolant channels are interleaved with the power stages. At least one of the bodies defines a passageway extending between adjacent channels to connect the adjacent channels in fluid communication.

Abstract: A power supply is provided. The power supply device includes a power module and a capacitor. The power module includes inverting circuitry and is configured to deliver electrical power to an electric machine. The capacitor is disposed adjacent to the power module and is arranged to limit voltage variation at the inverting circuitry input due to ripple current. The inverting circuitry and the capacitor are surrounded by a monolithic non-metal casing that provides voltage isolation between the power module and the capacitor.

Abstract: A power-electronics system includes a plurality of power modules each having a power stage and defining a side pocket. The power stages are stacked in an array such that the side pockets are interleaved with the power stages. A dummy module defines a first coolant pocket and is disposed within the array such that the first coolant pocket cooperates with one of the side pockets to define a coolant chamber.

Abstract: A power-module assembly includes a plurality of power modules that each have a power stage with opposing major sides and minor sides surrounded by a frame. The frame extends past the major sides and cooperates with the major sides to define pockets on each side of the power module. The modules are arranged in a stack such that pockets adjacent to each other cooperate to form coolant chambers interleaved with the modules.

Abstract: A vehicle power module assembly including a stacked array of module frames, a manifold, and a pair of endplates is provided. The stacked array of module frames may each define a passthrough in registration with other of the passthroughs to define a manifold cavity, a power stage cavity, and a plurality of outlets open to the respective passthroughs and oriented relative to the power stage cavities to deliver coolant therebetween. The manifold may be disposed within the manifold cavity and defines a manifold inlet open to an inlet chamber and manifold ports for alignment with the plurality of outlets. One of the endplates may define an inlet open to the manifold inlet and another one of the endplates may define an outlet open to a manifold outlet. The inlets, outlets, and ports are arranged with one another to provide a coolant path between the endplate inlet and endplate outlet.

Abstract: A vehicle power system may include a power module assembly having a plurality of alternating heatsinks and phase legs arranged in a deck. Each of the phase legs includes a semiconductor switch in contact with a dielectric layer. The dielectric layer is sandwiched between the switch and one of the heatsinks such that heat generated by the switch is transferred to the heatsink via the dielectric. At least one of the heatsinks may define a coolant channel. The coolant channel may be U-shaped. The coolant channel may have inlet and outlet regions. The inlet region may be opposite the outlet region. The coolant channel may have a divider to segregate ingress and egress coolant paths. The coolant channel may have obstructions to form a tortuous path. The obstructions may be wavy fins.

Abstract: A vehicle powertrain includes a stator defining a circular opening having an inner diameter, and a rotor to rotate within the circular opening such that a gap is formed between a rotor surface and the stator at the inner diameter. The powertrain further includes a repellant, coated on the stator and the rotor surface, to control fluid flow in the gap.

Abstract: A vehicle power module assembly includes a modular manifold, an upper frame, and a plurality of power stages. The modular manifold includes a first base unit defining an inlet chamber, a second base unit defining an outlet chamber, a mid-unit defining one or more ports open to the chambers, and an upper unit defining a first set of slots and a second set of slots in fluid communication with the chambers via the ports. The plurality of power stages is housed within the frame and each of the power stages are spaced from one another to define inner channels therebetween. The chambers, channels, and ports are arranged with one another such that coolant flowing through the inner channels is in thermal communication with the power stages. The mid-unit may further include flow guides each sized to partially extend into one of the inner channels.

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.

Abstract: Electronic devices are disclosed including hydrophobic or oleophobic coatings that control coolant flow therein or thereon. In at least one embodiment, an electric machine is provided including a stator core defining a cavity, windings disposed within the cavity and including end windings protruding from the cavity, and one or more layers of an oleophobic coating overlying the end windings and configured to control a flow of coolant over the end windings. A method may include applying one or more layers of a oleophobic coating to end windings of an electric machine stator such that the one or more layers control a flow of coolant over the end windings. The one or more layers may define coolant flow paths, which may direct coolant to areas of the electric machine requiring additional cooling, such as hot spots or neutral points.

Abstract: A vehicle power module assembly including an array of frames each defining a passthrough and step is provided. The frames may be stacked such that the passthroughs are in at least partial registration with one another and the steps align to define an inlet manifold having first and second chambers extending a length of the array. The chambers may be partially open to one another such that the steps influence a momentum of coolant traveling from the first to the second chamber. A pair of endplates may be disposed on either end of the array and configured to retain the frames therebetween. Each of the frames may further define a pair of channels and may be arranged with one another to define a power stage cavity therebetween. A power stage may be disposed within the power stage cavity.

Abstract: A power inverter includes a plurality of power modules each having a power stage encased in a frame that defines an opening. The power modules are stacked in an array with the power stages being spaced apart to define coolant chambers interleaved with the power stages. The openings cooperate to form a manifold cavity extending along a length of the stack and in fluid communication with the chambers. A manifold insert is disposed in the cavity and extends through the openings.

Abstract: A power inverter includes a plurality of power modules each having a power stage encased in a frame that defines an opening. The power modules are stacked in an array with the power stages being spaced apart to define coolant chambers interleaved with the power stages. The openings cooperate to form a manifold cavity extending along a length of the stack and in fluid communication with the chambers. A manifold insert is disposed in the cavity and extends through the openings.

Abstract: A vehicle power module assembly includes a modular manifold, an upper frame, and a plurality of power stages. The modular manifold includes a first base unit defining an inlet chamber, a second base unit defining an outlet chamber, a mid-unit defining one or more ports open to the chambers, and an upper unit defining a first set of slots and a second set of slots in fluid communication with the chambers via the ports. The plurality of power stages is housed within the frame and each of the power stages are spaced from one another to define inner channels therebetween. The chambers, channels, and ports are arranged with one another such that coolant flowing through the inner channels is in thermal communication with the power stages. The mid-unit may further include flow guides each sized to partially extend into one of the inner channels.