Abstract: A method of making a support arm includes heating a mold to a glass transition temperature of a thermoplastic material; injecting the thermoplastic material comprising a filler into the mold and allowing the thermoplastic material to conform to the mold; cooling the mold to an ejection temperature to form the support arm; and ejecting the support arm from the mold; wherein a cross-section of the support arm taken along a line from an inner edge to an outer edge of the support arm comprises a first “U” shaped portion and a second “U” shaped portion.

Abstract: A process for constructing a hybrid material part includes mixing a metal powder and a binder to form a compounded mixture, heating the compounded mixture, injecting the compounded mixture into a first mold to form a green part, and debinding the green part to form a brown part. The process further includes sintering the brown part to form a sintered part, and over-molding the sintered part with a plastic in a second mold of an injection molding machine to form the hybrid material part. A hybrid material pump part is disclosed as well.

Abstract: A method of making a support arm includes heating a mold to a glass transition temperature of a thermoplastic material; injecting the thermoplastic material comprising a filler into the mold and allowing the thermoplastic material to conform to the mold; cooling the mold to an ejection temperature to form the support arm; and ejecting the support arm from the mold; wherein a cross-section of the support arm taken along a line from an inner edge to an outer edge of the support arm comprises a first “U” shaped portion and a second “U” shaped portion.

Abstract: A housing system can comprise a plastic cover (12); a plastic base (14) comprising a floor (20) having sidewalls (22, 24); a first elevation (26); a second elevation (34); a first mounting column (40) located in a transformer end (32) of the plastic base (14) adjacent a major axis first sidewall (22); a second mounting column (42) located in the transformer end (32) of the plastic base (14) adjacent a major axis second sidewall (22); wherein the first and second mounting columns (40,42) have a top surface (44) that protrudes a distance from the floor (20), in the Z direction, in an amount greater than or equal to elevation walls (28,36), wherein the top surface (44) is configured to receive an attachment element (46). The housing system can also comprise a transformer (72), physically attached to the mounting columns; a capacitor (74); a fan (78), and a printed circuit board (80).

Abstract: In an embodiment, a support arm comprises: a thermoplastic material and a filler. A cross-section of the support arm taken along a line from an inner edge to an outer edge of the support arm comprises a modified I-shaped, an I/U-shaped, or a U-shaped cross-section.

Abstract: In an embodiment, a method of making a heat sink assembly can include: forming a heat sink assembly comprising a polymer heat sink around a metal insert, the polymer heat sink comprising a thermally conductive polymer material, wherein the heat sink assembly has a contact pressure between the polymer heat sink and the metal insert; and increasing the contact pressure. In an embodiment, a method of making a heat sink assembly includes: heating a mold and subsequently introducing a metal insert to the mold, wherein the metal insert has an insert temperature of 30° C. to 70° C. when it is inserted into the mold; closing the mold; and in less than or equal to 10 seconds of closing the mold, over-molding the metal insert with a thermally conductive polymer material to form a heat sink assembly.

Abstract: In an embodiment, a support arm includes: a thermoplastic material and a filler. A cross-section of the support arm taken along a line from an inner edge to an outer edge of the support arm comprises a modified I-shaped, a I/U-shaped, or a U-shaped cross-section.

Abstract: A housing system can comprise a plastic cover (12); a plastic base (14) comprising a floor (20) having sidewalls (22, 24); a first elevation (26); a second elevation (34); a first mounting column (40) located in a transformer end (32) of the plastic base (14) adjacent a major axis first sidewall (22); a second mounting column (42) located in the transformer end (32) of the plastic base (14) adjacent a major axis second sidewall (22); wherein the first and second mounting columns (40,42) have a top surface (44) that protrudes a distance from the floor (20), in the Z direction, in an amount greater than or equal to elevation walls (28,36), wherein the top surface (44) is configured to receive an attachment element (46). The housing system can also comprise a transformer (72), physically attached to the mounting columns; a capacitor (74); a fan (78), and a printed circuit board (80).

Abstract: A housing system can comprise a plastic cover (12); a plastic base (14) comprising a floor (20) having side walls (22, 24); a first elevation (26); a second elevation (34); a first mounting column (40) located in a transformer end (32) of the plastic base (14) adjacent a major axis first sidewall (22); a second mounting column (42) located in the transformer end (32) of the plastic base (14) adjacent a major axis second sidewall (22); wherein the first and second mounting columns (40,42) have a top surface (44) that protrudes a distance from the floor (20), in the Z direction, in an amount greater than or equal to elevation walls (28,36), wherein the top surface (44) is configured to receive an attachment element (46). The housing system can also comprise a transformer (72), physically attached to the mounting columns; a capacitor (74); a fan (78), and a printed circuit board (80).

Abstract: In an embodiment, a power inverter casing, comprises: a body having a first component removably attached to a second component, wherein, when joined, a recess is formed therebetween; a member removably attached to the first component and the second component opposite the recess; and a handle located in the recess and removably attached to the first component and the second component; wherein the member contains a first member illuminating element, and/or the recess contains a recess illuminating element, and/or the handle contains a handle illuminating element.

Abstract: A housing system can comprise a plastic cover (12); a plastic base (14) comprising a floor (20) having side walls (22, 24); a first elevation (26); a second elevation (34); a first mounting column (40) located in a transformer end (32) of the plastic base (14) adjacent a major axis first sidewall (22); a second mounting column (42) located in the transformer end (32) of the plastic base (14) adjacent a major axis second sidewall (22); wherein the first and second mounting columns (40,42) have a top surface (44) that protrudes a distance from the floor (20), in the Z direction, in an amount greater than or equal to elevation walls (28,36), wherein the top surface (44) is configured to receive an attachment element (46). The housing system can also comprise a transformer (72), physically attached to the mounting columns; a capacitor (74); a fan (78), and a printed circuit board (80).

Abstract: In an embodiment, a method of making a heat sink assembly (10) can comprise: forming an heat sink assembly (10) comprising a polymer heat sink (14) around a metal insert (12), the polymer heat sink (14) comprising a thermally conductive polymer material, wherein the heat sink assembly (10) has a contact pressure between the polymer heat sink (14) and the metal insert (12); and increasing the contact pressure. In an embodiment, a method of making a heat sink assembly (10), comprises: heating a mold and subsequently introducing a metal insert to the mold, wherein the metal insert has an insert temperature of 30° C. to 70° C. when it is inserted into the mold; closing the mold; and in less than or equal to 10 seconds of closing the mold, over-molding the metal insert with a thermally conductive polymer material to form a heat sink assembly (10).

Abstract: In an embodiment, a support arm comprises: a thermoplastic material and a filler. A cross-section of the support arm taken along a line from an inner edge to an outer edge of the support arm comprises a modified I-shaped, a I/U-shaped, or a U-shaped cross-section.

Abstract: In an embodiment, a power inverter casing, comprises: a body having a first component removably attached to a second component, wherein, when joined, a recess is formed therebetween; a member removably attached to the first component and the second component opposite the recess; and a handle located in the recess and removably attached to the first component and the second component; wherein the member contains a first member illuminating element, and/or the recess contains a recess illuminating element, and/or the handle contains a handle illuminating element.