Abstract: A busbar assembly is disclosed that includes a carrier, and a plurality of conductors arranged within the carrier such that at least a portion of each of the plurality of conductors are exposed in a radial direction and define electrical contact sites. The carrier can be formed by molding the carrier about the plurality of conductors.

Abstract: A busbar assembly is disclosed herein. The assembly includes a ring body having a plurality of openings extending in an axial direction and configured to receive electrical wire connections, and a plurality of phase conductors. A high-voltage connection portion is also included in this same body. The high-voltage connection portion includes a plurality of high voltage conductors each configured to engage a respective one of the plurality of phase conductors. A plurality of connectors are each attached to a respective one of the plurality of high voltage conductors. A seal is arranged on a periphery of the high-voltage connection portion to incorporate the busbar into one combined simple design.

Abstract: An apparatus and methods are provided for a segmented stator comprising over-molded windings and an incorporated bus bar for a multi-phase electric motor. The segmented stator comprises a plurality of stator segments that are arranged into a circular configuration. Each stator segment comprises a divided core that includes a core back portion and a core tooth portion. An insulator is disposed on at least the core tooth portion, and a winding of magnet wire is disposed on the insulator. An over-molded encapsulation is applied to fixate the divided core and the winding. A bus bar is incorporated into the stator segments and placed into electrical communication with the windings. The bus bar includes annular conductors that may be over-molded such that the bus bar is encapsulated within the segmented stator. Connectors coupled with the bus bar are configured for passing an electric current to the stator segments.

Abstract: A busbar assembly is disclosed herein. The assembly includes a ring body having a plurality of openings extending in an axial direction and configured to receive electrical wire connections, and a plurality of phase conductors. A high-voltage connection portion is also included in this same body. The high-voltage connection portion includes a plurality of high voltage conductors each configured to engage a respective one of the plurality of phase conductors. A plurality of connectors are each attached to a respective one of the plurality of high voltage conductors. A seal is arranged on a periphery of the high-voltage connection portion to incorporate the busbar into one combined simple design.

Abstract: A busbar assembly is disclosed that includes a carrier, and a plurality of conductors arranged within the carrier such that at least a portion of each of the plurality of conductors are exposed in a radial direction and define electrical contact sites.

Abstract: A hybrid module includes a motor housing, an electric motor, a shaft, a torque converter housing, a backing plate, a piston, and a hub. The motor housing includes a first flow passage. The electric motor includes a rotor and stator. The shaft is drivingly engaged with the rotor and includes a second flow passage arranged for fluid communication with the first flow passage. The torque converter housing is drivingly engaged with the rotor. The backing plate is fixed to the torque converter housing. The piston is sealed to the torque converter housing and the backing plate and forms at least a portion of a first fluid chamber and a second fluid chamber. The hub includes a third flow passage arranged for fluid communication with the second flow passage and one of the first fluid chamber or the second fluid chamber.

Abstract: A torque converter includes a turbine disposed in a hydrodynamic chamber. A bypass clutch has an apply chamber fluidly isolated from the hydrodynamic chamber. A first hydraulic passage is in fluid communication with the apply chamber. A variable-pitch stator including blades controllable by an actuator that has a chamber in fluid communication with the first hydraulic passage.

Abstract: A cover for a torque converter and an electric motor, comprising a cover surface that includes a first cluster of perforations that are located adjacent to a first end of a rotor of the motor, wherein the perforations are arranged to transfer fluid from the torque converter to a rotor of the electric motor.

Abstract: A disk assembly of a torque converter bypass clutch includes a disk defining a circular spring cavity and a plurality of arc springs circumferentially arranged in the cavity with gaps defined between adjacent ones of the arc springs. Each of the springs includes an end cap fitted on an end of the spring. Spring connectors are each disposed in one of the gaps and include an end received within a corresponding one of the end caps.

Abstract: A torque converter includes an impeller, a turbine axially movable relative to the impeller, and a variable-pitch stator. The stator includes a hub and variable-pitch blades circumferentially arranged on the hub. Each of the blades are rotatable between first and second positions in response to axial movement of the turbine.

Abstract: A torque converter includes an impeller, a turbine axially movable relative to the impeller, and a variable-pitch stator. The stator includes a hub and variable-pitch blades circumferentially arranged on the hub. Each of the blades are rotatable between first and second positions in response to axial movement of the turbine.

Abstract: A torque converter includes a turbine disposed in a hydrodynamic chamber. A bypass clutch has an apply chamber fluidly isolated from the hydrodynamic chamber. A first hydraulic passage is in fluid communication with the apply chamber. A variable-pitch stator including blades controllable by an actuator that has a chamber in fluid communication with the first hydraulic passage.

Abstract: A torque converter comprising: a damper assembly including a spring retainer; and, a turbine assembly connected to the damper assembly, the turbine assembly including: a turbine shell including an axially movable turbine piston; a drive plate fixed to the turbine piston; and a diaphragm spring, the drive plate having openings for receiving the diaphragm spring; the diaphragm spring acting on the turbine piston with a preload force. In an example aspect, the diaphragm spring includes a plurality of radially inward tabs and the drive plate includes a plurality of openings for receiving the radially inward tabs.

Abstract: A torque converter, including: a cover; a lock-up clutch with a piston plate; an output hub; a first hub including a through-bore; a chamber bounded by the turbine; an apply chamber bounded by the piston plate; a release chamber bounded by the cover, the first hub, and the piston plate; a first flow path; a through-bore through the first hub; and a second flow path. The second flow path: is sealed from the first chamber; passes through the through-bore; and includes a portion circumferentially aligned with the first flow path. A line in an axial direction passes through the through-bore without intersecting the first hub. For a lock-up mode, pressurized fluid in the apply chamber displaces the piston plate in a first axial direction. For a torque converter mode, pressurized fluid in the release chamber displaces the piston plate in a second axial direction.

Abstract: A cover for a torque converter and an electric motor, comprising a cover surface that includes a first cluster of perforations that are located adjacent to a first end of a rotor of the motor, wherein the perforations are arranged to transfer fluid from the torque converter to a rotor of the electric motor.

Abstract: A disk assembly of a torque converter bypass clutch includes a disk defining a circular spring cavity and a plurality of arc springs circumferentially arranged in the cavity with gaps defined between adjacent ones of the arc springs. Each of the springs includes an end cap fitted on an end of the spring. Spring connectors are each disposed in one of the gaps and include an end received within a corresponding one of the end caps.

Abstract: A torque converter, including: a cover; a lock-up clutch with a piston plate; an output hub; a first hub including a through-bore; a chamber bounded by the turbine; an apply chamber bounded by the piston plate; a release chamber bounded by the cover, the first hub, and the piston plate; a first flow path; a through-bore through the first hub; and a second flow path. The second flow path: is sealed from the first chamber; passes through the through-bore; and includes a portion circumferentially aligned with the first flow path. A line in an axial direction passes through the through-bore without intersecting the first hub. For a lock-up mode, pressurized fluid in the apply chamber displaces the piston plate in a first axial direction. For a torque converter mode, pressurized fluid in the release chamber displaces the piston plate in a second axial direction.

Abstract: A hybrid module includes a motor housing, an electric motor, a shaft, a torque converter housing, a backing plate, a piston, and a hub. The motor housing includes a first flow passage. The electric motor includes a rotor and stator. The shaft is drivingly engaged with the rotor and includes a second flow passage arranged for fluid communication with the first flow passage. The torque converter housing is drivingly engaged with the rotor. The backing plate is fixed to the torque converter housing. The piston is sealed to the torque converter housing and the backing plate and forms at least a portion of a first fluid chamber and a second fluid chamber. The hub includes a third flow passage arranged for fluid communication with the second flow passage and one of the first fluid chamber or the second fluid chamber.

Abstract: A torque converter is provided. The torque converter includes an impeller including a plurality of impeller blades and a radially extending wall radially outside of the impeller blades and a turbine piston axially movable with respect to the impeller. The turbine piston includes a plurality of turbine blades and an outer radial extension radially outside of the turbine blades. The torque converter also includes a clutch assembly axially between the radially extending wall of the impeller and the outer radial extension of the turbine piston. The clutch assembly includes a first clutch plate rotationally fixed to the impeller and a second clutch plate rotationally fixed to the turbine piston. A portion of the clutch assembly extends between the turbine blades or the impeller blades. A method of constructing a torque converter is also provided.

Abstract: A torque converter is provided. The torque converter includes an impeller including a plurality of impeller blades and a radially extending wall radially outside of the impeller blades and a turbine piston axially movable with respect to the impeller. The turbine piston includes a plurality of turbine blades and an outer radial extension radially outside of the turbine blades. The torque converter also includes a clutch assembly axially between the radially extending wall of the impeller and the outer radial extension of the turbine piston. The clutch assembly includes a first clutch plate rotationally fixed to the impeller and a second clutch plate rotationally fixed to the turbine piston. A portion of the clutch assembly extends between the turbine blades or the impeller blades. A method of constructing a torque converter is also provided.