Abstract: A method for improving thermal conduction in a stator having electrically conductive windings wound in a plurality of gaps formed between adjacent pairs of a plurality of teeth of the stator. A plurality of interstitial spaces are formed within each of the gaps during winding of the electrically conductive windings around the teeth. A plug is arranged within each one of the gaps to close off slot openings. A thermally conductive filler compound is injected into each gap under sufficient pressure to at least substantially fill the interstitial spaces within each gap and to at least substantially encapsulate the electrically conductive windings. The thermally conductive filler compound is then allowed to set.

Abstract: A battery pack apparatus comprising a first cell bank and a laminated cooling plate. The first cell bank includes a first tray and at least one battery cell coupled to the tray. The laminated cooling plate being in contact with the first cell bank and including a plurality of face sheets and a plurality of internal sheets. The face sheets forming a fluid inlet and a fluid outlet. The plurality of internal sheets forming a plurality of fluid passages connecting the fluid inlet to the fluid outlet. The internal sheets further formed to include fluid pathways defining the fluid passages wherein none of the fluid pathways individually defining an uninterrupted flow path.

Abstract: A battery pack apparatus has a plurality of battery cell units that are stacked together in generally parallel relation. The battery cell units are configured to define converging air flow spaces therebetween. An air inlet header provides a converging air inlet plenum that is situated adjacent one side of the battery cell units and an air outlet header provides a diverging air outlet plenum that is situated adjacent an opposite side of the battery cell units. A blower or fan forces air into the air inlet plenum. The air flows through the air flow spaces between the battery cell units to cool the battery cell units. The speed of the air increases as it advances through the air inlet plenum and the plurality of air flow spaces.

Abstract: A battery pack apparatus comprising a first cell bank and a laminated cooling plate. The first cell bank includes a first tray and at least one battery cell coupled to the tray. The laminated cooling plate being in contact with the first cell bank and including a plurality of face sheets and a plurality of internal sheets. The face sheets forming a fluid inlet and a fluid outlet. The plurality of internal sheets forming a plurality of fluid passages connecting the fluid inlet to the fluid outlet. The internal sheets further formed to include fluid pathways defining the fluid passages wherein none of the fluid pathways individually defining an uninterrupted flow path.

Abstract: A battery pack apparatus has a plurality of battery cell units that are stacked together in generally parallel relation. The battery cell units are configured to define converging air flow spaces therebetween. An air inlet header provides a converging air inlet plenum that is situated adjacent one side of the battery cell units and an air outlet header provides a diverging air outlet plenum that is situated adjacent an opposite side of the battery cell units. A blower or fan forces air into the air inlet plenum. The air flows through the air flow spaces between the battery cell units to cool the battery cell units. The speed of the air increases as it advances through the air inlet plenum and the plurality of air flow spaces.

Abstract: A battery pack apparatus has a plurality of battery cell units that are stacked together in generally parallel relation. The battery cell units are configured to define converging air flow spaces therebetween. An air inlet header provides a converging air inlet plenum that is situated adjacent one side of the battery cell units and an air outlet header provides a diverging air outlet plenum that is situated adjacent an opposite side of the battery cell units. A blower or fan forces air into the air inlet plenum. The air flows through the air flow spaces between the battery cell units to cool the battery cell units. The speed of the air increases as it advances through the air inlet plenum and the plurality of air flow spaces.

Abstract: A battery pack apparatus has a plurality of battery cell units that are stacked together in generally parallel relation. The battery cell units are configured to define converging air flow spaces therebetween. An air inlet header provides a converging air inlet plenum that is situated adjacent one side of the battery cell units and an air outlet header provides a diverging air outlet plenum that is situated adjacent an opposite side of the battery cell units. A blower or fan forces air into the air inlet plenum. The air flows through the air flow spaces between the battery cell units to cool the battery cell units. The speed of the air increases as it advances through the air inlet plenum and the plurality of air flow spaces.

Abstract: A battery pack apparatus has a plurality of battery cell units that are stacked together in generally parallel relation. The battery cell units are configured to define converging air flow spaces therebetween. An air inlet header provides a converging air inlet plenum that is situated adjacent one side of the battery cell units and an air outlet header provides a diverging air outlet plenum that is situated adjacent an opposite side of the battery cell units. A blower or fan forces air into the air inlet plenum. The air flows through the air flow spaces between the battery cell units to cool the battery cell units. The speed of the air increases as it advances through the air inlet plenum and the plurality of air flow spaces.

Abstract: A battery pack apparatus has a plurality of battery cell units that are stacked together in generally parallel relation. The battery cell units are configured to define converging air flow spaces therebetween. An air inlet header provides a converging air inlet plenum that is situated adjacent one side of the battery cell units and an air outlet header provides a diverging air outlet plenum that is situated adjacent an opposite side of the battery cell units. A blower or fan forces air into the air inlet plenum. The air flows through the air flow spaces between the battery cell units to cool the battery cell units. The speed of the air increases as it advances through the air inlet plenum and the plurality of air flow spaces.

Abstract: An electronics assembly is provided having a substrate and at least one electronics package supported on the substrate. The electronics package also has electrical circuitry and first and second side surfaces. The assembly further includes a first heat sink device positioned in thermal communication with the first side surface of the electronics package, and a second heat sink device positioned in thermal communication with the second side surface of the electronics package.

Abstract: An electronics assembly 10 is provided, including a housing 12 and at least one electronic power device 18 positioned within. A heat sink device 34 is positioned within the housing 12 and is in thermal communication with the electronic power device 18. The heat sink device 34 includes a fluid vessel 44, a fluid input port 50, a fluid output port 52, and at least one fin insert 60 brazed into the fluid vessel 44. The heat sink device 34 is in fluid communication with an automotive radiator 46 such that coolant 48 flows from the automotive radiator 46 through the fluid vessel 44 thereby cooling the electronic power device 18.

Abstract: A battery pack is provided that includes a case and at least one battery module disposed within the case. The battery pack further includes a flexible circuit to which the battery module may be electrically coupled. The flexible circuit includes a plurality of airflow openings configured to distribute air throughout the battery pack. In a preferred embodiment, the airflow openings vary in size relative to their proximity to an air source.

Abstract: A mounting apparatus for an electromagnetic device such as a transformer of inductor includes a generally planar metallic plate as a first heat sink, and a metallic mounting cup as a second heat sink. The mounting cup includes a cavity configured to receive the electromagnetic device, the cavity being defined by a base, and an axially-extending annular sidewall extending from the base to a flange portion of the mounting cup. The mounting cup includes first and second passages for allowing the leads of first and second windings of the electromagnetic device to be routed out of the cavity. The cavity is filled with a polyurethane potting resin, and the mounting cup, including the potted electromagnetic device, is mounted to the plate heat sink using fasteners. The mounting cup, which surrounds the electromagnetic device, in combination with the potting resin provides improved thermal transfer to the plate heat sink, as well as providing resistance to vibration and shocks.

Abstract: An apparatus for supplying an electrical charge to a vehicle having a plurality of contact members and a plurality of elastic members secured to the inner surface of the plurality of contact members at one end and a plurality of relays at the other end. The relays are suspended behind the inner surface of the plurality of contact members and the elastic members allow the plurality of relays to travel in a range defined by a first position and a second position and the relays are in a facially spaced relationship with the inner surface of the contact members when the relay is in the first position and the relays make contact with the inner surface of the contact members when the relay is the second position and a power conduit connects the plurality of relays to an electrical supply.

Abstract: An annular, cast housing for a dynamoelectric machine defines a single internal, circumferential, liquid coolant circulation passage having a main portion of flat, rectangular cross-section having a width extending axially across the housing and a length extending circumferentially around a majority of the housing and, at opposite ends of the main portion, transitional portions narrowing in width from opposite axial sides so that the transitional portions pass each other on the narrowing sides and smoothly convert from the flat, rectangular cross-section to a circular cross-section. The transitional portions end in conduits substantially aligned with each other and oriented in substantially opposite directions.

Abstract: A valve-regulated, deep-cycling, gas-recombinant, high energy, lead-acid battery operating at superambient temperatures and internal pressures wherein the sidewalls of the battery container (i.e., intersected by the intercell partitions) are abnormally thin and reinforced against bulging by ribs which project from the container and extend in a direction transverse the intercell partitions. The ribs will preferably have a sinuous shape for optimal strength and heat transfer from the battery.

Abstract: A new flat cell battery design is provided which incorporates a cathode and an anode terminal which are located in respective corners of a battery body. By locating the cathode and anode terminals in respective corners of the flat cell battery, the storage capacity and energy density of the battery are increased compared to conventional flat cell batteries. The corner terminal design of the present invention significantly improves packaging efficiency over common-edge terminals. In addition to increased volume efficiency, corner terminals improve thermal and electrical distribution properties of the battery. Physical separation of the terminals to adjacent or opposite corners also reduces the probability of inadvertent external short-circuit, resulting in improved safety.