Patents by Inventor Franco Leonardi

Franco Leonardi has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Publication number: 20190288574
    Abstract: An electric machine includes a stator core defining slots and hairpins disposed in the slots. The hairpins are selectively joined at connections to form windings that include at least first and second radial layers. Each connection is disposed in one of the layers. The connections are staggered such that the connections of the first layer are circumferentially offset from the connections of the second layer to increase clearance for tooling that forms the connections.
    Type: Application
    Filed: March 13, 2018
    Publication date: September 19, 2019
    Inventors: Franco LEONARDI, Feng LIANG
  • Publication number: 20190222078
    Abstract: An electric machine includes a stator core defining slots having radial layers that each include adjacent first and second pin positions. Pins are disposed in corresponding ones of the slots and are interconnected to form a winding path. The path occupies the first and second positions of each layer, and, for each of the corresponding slots, the pins are in a same layer.
    Type: Application
    Filed: January 15, 2018
    Publication date: July 18, 2019
    Inventors: Feng LIANG, Franco LEONARDI, Becky Sue MORRIS, Michael W. Degner
  • Publication number: 20190222091
    Abstract: A vehicle electric machine assembly including a stator core and a terminal block is provided. The stator core includes one or more three-phase terminals connected to end windings. The terminal block includes a connector for each of the three-phase terminals. A portion of the end windings extending from the stator core, the three-phase terminals, and the terminal block are overmolded as a single unit such that a portion of each of the connectors is exposed for connection to an inverter. The terminal block may further include one or more threaded apertures, each sized to receive a threaded stud to facilitate an electrical connection between one of the one or more three-phase terminals and the inverter. Each of the one or more three-phase terminals may extend axially along an axis substantially parallel to a central axis of a rotor disposed within a cavity defined by the stator core.
    Type: Application
    Filed: January 12, 2018
    Publication date: July 18, 2019
    Applicant: Ford Global Technologies, LLC
    Inventors: Michael W. Degner, Prasad Dev Hanumalagutti, Franco Leonardi
  • Publication number: 20190140501
    Abstract: A rotor assembly has a rotor including a plurality of laminations each defining a plurality of poles arranged such that values of a pair of angles corresponding to each of the poles and defined between a magnetic axis of the pole and respective interpolar axes adjacent thereto are different. The values of the pairs define a repeating sequence around the lamination. The angles opposite an axis of rotation of the rotor are equal.
    Type: Application
    Filed: November 9, 2017
    Publication date: May 9, 2019
    Inventors: Franco Leonardi, Feng Liang, Michael W. Degner
  • Patent number: 10211689
    Abstract: An electric machine rotor includes a lamination configured to rotate about a central axis and a plurality of pairs of permanent magnets. Each pair of permanent magnets is arranged in a V-shaped pattern and affixed within the lamination to create a magnetic field for rotation of the lamination. The lamination also includes an outer periphery spanning circumferentially outside of the permanent magnets, wherein a mass-reduction cutout extends through the lamination nested within in a V-shape defined by the permanent magnets adjacent to an outer surface of the rotor. The lamination further includes a stress-reduction slot that extends through the outer periphery of the rotor.
    Type: Grant
    Filed: March 9, 2016
    Date of Patent: February 19, 2019
    Assignee: Ford Global Technologies, LLC
    Inventors: Feng Liang, Benedikt Groschup, Franco Leonardi
  • Patent number: 10135319
    Abstract: A vehicle electric machine includes a stator having an end face and a yoke region defining a channel. End windings are adjacent to the end face. An annular cover has inner and outer walls defining an annular cavity configured to receive the end windings. The channel opens into the cavity, and a radial distance between the inner and outer walls is less than or equal to a radial length of the end face.
    Type: Grant
    Filed: March 17, 2016
    Date of Patent: November 20, 2018
    Assignee: Ford Global Technologies, LLC
    Inventors: Prasad Dev Hanumalagutti, Michael W. Degner, Franco Leonardi, Edward Chan-Jiun Jih
  • Patent number: 10097066
    Abstract: An electric machine for a vehicle includes a stator having slots and a yolk region defining a plurality of channels extending between the opposing end faces of the stator. Windings extend through the slots and have end windings adjacent to the end faces. A rotor is disposed within the stator. The electric machine also includes first and second annular covers each defining a cavity having a plurality of walls partitioning the cavity into a plurality of cooling chambers that are circumferentially isolated from each other. Each of the covers is attached to one of the end faces such that a corresponding one of the end windings is disposed within one of the cavities, and such that each of the channels is in direct fluid communication with a corresponding one of the cooling chambers of the first cover and with a corresponding one of the cooling chambers of the second cover.
    Type: Grant
    Filed: March 17, 2016
    Date of Patent: October 9, 2018
    Assignee: Ford Global Technologies, LLC
    Inventors: Prasad Dev Hanumalagutti, Michael W. Degner, Franco Leonardi, Edward Chan-Jiun Jih
  • Patent number: 10086538
    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.
    Type: Grant
    Filed: March 17, 2016
    Date of Patent: October 2, 2018
    Assignee: Ford Global Technologies, LLC
    Inventors: Prasad Dev Hanumalagutti, Michael W. Degner, Edward Chan-Jiun Jih, Guangyin Lei, Franco Leonardi
  • Patent number: 10038351
    Abstract: An electric machine for an electrified vehicle is provided. The electric machine may include a stator, a ring plate, an encasement, and a fastener. The stator defines a cavity, a stator recess about a portion of the cavity, and a stator aperture. The stator may include windings disposed within and partially protruding out of the cavity. The ring plate may be sized for disposal within the stator recess, and may define a tab and a plate aperture for alignment with the stator aperture. The encasement may define a key sized for engagement with the tab to secure the encasement to the ring plate, and a closed coolant channel. The fastener may be sized for insertion within the apertures to secure the plate to the stator. The stator, ring plate, and encasement may be arranged with one another such that the partially protruding windings are disposed within the closed coolant channel.
    Type: Grant
    Filed: March 17, 2016
    Date of Patent: July 31, 2018
    Assignee: Ford Global Technologies, LLC
    Inventors: Prasad Dev Hanumalagutti, Michael W. Degner, Franco Leonardi
  • Patent number: 10008908
    Abstract: A vehicle electric machine includes a rotor, and a stator having a core with an end face and end windings adjacent to the end face. An annular cooling trough has an outer sidewall and a bottom. The trough is connected to the end face such that the bottom engages the core, and the sidewall, bottom and end face cooperate to define an open channel around the end windings configured to receive fluid therein.
    Type: Grant
    Filed: March 17, 2016
    Date of Patent: June 26, 2018
    Assignee: Ford Global Technologies, LLC
    Inventors: Prasad Dev Hanumalagutti, Michael W. Degner, Franco Leonardi
  • Publication number: 20180054107
    Abstract: An electric machine includes a stator with a core having an end face and a plurality of conductors forming windings that extend adjacent to the end face defining end turns having a toroidal outline. The end turns are formed to define at least one channel in the end turns that traverses the end turns for increasing a surface area for fluid contact and directing a flow of fluid along the toroidal surface.
    Type: Application
    Filed: August 22, 2016
    Publication date: February 22, 2018
    Inventors: Franco LEONARDI, Prasad Dev HANUMALAGUTTI, Michael W. DEGNER
  • Publication number: 20170310189
    Abstract: A vehicle electric machine may include a rotor. The rotor may cooperate with a stator including a core having an end face, and end windings extending from the end face. A cooling tunnel may encase the end windings, sealing against the end face at opposing sides of the end windings, and defining an inlet configured to receive coolant. The cooling tunnel may be arranged to contain the coolant during passage over the end windings and direct the coolant toward an outlet.
    Type: Application
    Filed: April 25, 2016
    Publication date: October 26, 2017
    Inventors: Prasad Dev Hanumalagutti, Michael W. Degner, Franco Leonardi
  • Publication number: 20170271955
    Abstract: A vehicle electric machine includes a stator having an end face and a yoke region defining a channel. End windings are adjacent to the end face. An annular cover has inner and outer walls defining an annular cavity configured to receive the end windings. The channel opens into the cavity, and a radial distance between the inner and outer walls is less than or equal to a radial length of the end face.
    Type: Application
    Filed: March 17, 2016
    Publication date: September 21, 2017
    Inventors: Prasad Dev HANUMALAGUTTI, Michael W. DEGNER, Franco LEONARDI, Edward Chan-Jiun JIH
  • Publication number: 20170267055
    Abstract: An encasement of an electric machine of an electrified vehicle is provided. The encasement may include a base sidewall, an inner sidewall, and an outer sidewall. The inner sidewall may extend in a circular pattern about the base sidewall. The outer sidewall may extend from the base sidewall and may be spaced apart from the inner sidewall to define a coolant channel at least partially surrounding end windings of a stator of the electric machine. The base sidewall may define features between the sidewalls to promote turbulence of coolant flowing through the coolant channel. The base sidewall may define a meandering trough between the sidewalls to form a predetermined coolant path relative to a location of the end windings.
    Type: Application
    Filed: March 17, 2016
    Publication date: September 21, 2017
    Inventors: Prasad Dev Hanumalagutti, Michael W. Degner, Franco Leonardi
  • Publication number: 20170271957
    Abstract: A vehicle electric machine includes a rotor, and a stator having a core with an end face and end windings adjacent to the end face. An annular cooling trough has an outer sidewall and a bottom. The trough is connected to the end face such that the bottom engages the core, and the sidewall, bottom and end face cooperate to define an open channel around the end windings configured to receive fluid therein.
    Type: Application
    Filed: March 17, 2016
    Publication date: September 21, 2017
    Inventors: Prasad Dev HANUMALAGUTTI, Michael W. DEGNER, Franco LEONARDI
  • Publication number: 20170271956
    Abstract: An electric machine for a vehicle includes a stator having slots and a yolk region defining a plurality of channels extending between the opposing end faces of the stator. Windings extend through the slots and have end windings adjacent to the end faces. A rotor is disposed within the stator. The electric machine also includes first and second annular covers each defining a cavity having a plurality of walls partitioning the cavity into a plurality of cooling chambers that are circumferentially isolated from each other. Each of the covers is attached to one of the end faces such that a corresponding one of the end windings is disposed within one of the cavities, and such that each of the channels is in direct fluid communication with a corresponding one of the cooling chambers of the first cover and with a corresponding one of the cooling chambers of the second cover.
    Type: Application
    Filed: March 17, 2016
    Publication date: September 21, 2017
    Inventors: Prasad Dev HANUMALAGUTTI, Michael W. DEGNER, Franco LEONARDI, Edward Chan-Jiun JIH
  • Publication number: 20170271951
    Abstract: An electric machine for an electrified vehicle is provided. The electric machine may include a stator, a ring plate, an encasement, and a fastener. The stator defines a cavity, a stator recess about a portion of the cavity, and a stator aperture. The stator may include windings disposed within and partially protruding out of the cavity. The ring plate may be sized for disposal within the stator recess, and may define a tab and a plate aperture for alignment with the stator aperture. The encasement may define a key sized for engagement with the tab to secure the encasement to the ring plate, and a closed coolant channel. The fastener may be sized for insertion within the apertures to secure the plate to the stator. The stator, ring plate, and encasement may be arranged with one another such that the partially protruding windings are disposed within the closed coolant channel.
    Type: Application
    Filed: March 17, 2016
    Publication date: September 21, 2017
    Inventors: Prasad Dev Hanumalagutti, Michael W. Degner, Franco Leonardi
  • Publication number: 20170271940
    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.
    Type: Application
    Filed: March 17, 2016
    Publication date: September 21, 2017
    Inventors: Prasad Dev Hanumalagutti, Michael W. Degner, Edward Chan-Jiun Jih, Guangyin Lei, Franco Leonardi
  • Publication number: 20170264153
    Abstract: A rotor may include a planar lamination having permanent magnets arranged therein, and an inner edge defining an opening configured to receive a driveshaft. The planar lamination may include a driveshaft key, and a relief notch and scallop disposed on each side of the driveshaft key. The relief notch and scallop may distribute stress imparted to the driveshaft key and reduce deformation due to centrifugal loads during rotation of the rotor. The relief notches may be next to the driveshaft key. The relief notches may be sandwiched between the scallops. The inner edge may include additional scallops.
    Type: Application
    Filed: March 9, 2016
    Publication date: September 14, 2017
    Inventors: Benedikt Groschup, Franco Leonardi
  • Publication number: 20170264152
    Abstract: An electric machine rotor includes a lamination configured to rotate about a central axis and a plurality of pairs of permanent magnets. Each pair of permanent magnets is arranged in a V-shaped pattern and affixed within the lamination to create a magnetic field for rotation of the lamination. The lamination also includes an outer periphery spanning circumferentially outside of the permanent magnets, wherein a mass-reduction cutout extends through the lamination nested within in a V-shape defined by the permanent magnets adjacent to an outer surface of the rotor. The lamination further includes a stress-reduction slot that extends through the outer periphery of the rotor.
    Type: Application
    Filed: March 9, 2016
    Publication date: September 14, 2017
    Inventors: Feng Liang, Benedikt Groschup, Franco Leonardi