Abstract: Cooling systems and methods are provided for an integrated electric motor-inverter, where the integrated electric motor-inverter includes a housing, a motor, and an inverter, the motor and the inverter are disposed within the housing, and the motor includes a stator. The system includes a cooling jacket, a first coolant, a condenser, a spray head, and a second coolant. The cooling jacket is disposed concentric to the stator and includes an inner wall and an outer wall. The inner wall is in direct contact with the stator. The first coolant is disposed between the cooling jacket inner and outer walls. The condenser is disposed concentric to the cooling jacket. The spray head is disposed adjacent the inverter. The second coolant is in flow communication with the spray head.

Abstract: An inverter assembly includes a housing and a substrate disposed in the housing. The substrate includes at least a first conductive layer patterned to include an alternating current (AC) path and a direct current (DC) path. A plurality of inverter switches is mounted on the substrate and electrically coupled to the AC path and the DC path.

Abstract: Cooling systems and methods are provided for an integrated electric motor-inverter, where the integrated electric motor-inverter includes a housing, a motor, and an inverter, the motor and the inverter are disposed within the housing, and the motor includes a stator. The system includes a cooling jacket, a first coolant, a condenser, a spray head, and a second coolant. The cooling jacket is disposed concentric to the stator and includes an inner wall and an outer wall. The inner wall is in direct contact with the stator. The first coolant is disposed between the cooling jacket inner and outer walls. The condenser is disposed concentric to the cooling jacket. The spray head is disposed adjacent the inverter. The second coolant is in flow communication with the spray head.

Abstract: An inverter assembly includes a housing and a substrate disposed in the housing. The substrate includes at least a first conductive layer patterned to include an alternating current (AC) path and a direct current (DC) path. A plurality of inverter switches is mounted on the substrate and electrically coupled to the AC path and the DC path.

Abstract: Power electronics for electric traction motors used to drive automotive vehicles are cooled in a closed system by spraying a dielectric liquid coolant directly onto inverter circuitry. The liquid coolant changes phase and vaporizes as it absorbs heat from power transistors in inverter circuitry comprising the power electronics. The resultant vapor is condensed back to a liquid in a heat exchange arrangement having pipes carrying a second coolant from a radiator used to cool an engine or fuel cell stack in the automotive vehicle. Overspray coolant, which remains liquid, can also be cooled by the heat exchange arrangement. By utilizing the latent heat of evaporation of the dielectric coolant and increasing the rate recycling of the coolant as power output increases, temperature increases in the power electronics are controlled.

Abstract: Methods and apparatus are provided for charging a high-voltage battery of a hybrid electric vehicle. The high-voltage battery charging apparatus comprises a battery charger configured to provide electrical energy, a battery module configured to store the electrical energy provided by the battery charger, and a high-voltage bus coupled to the battery charger and the battery module, which is configured to transmit the electrical energy from the battery charger and battery module to the electrical system of the hybrid electric vehicle. In addition, the high-voltage battery charging apparatus comprises a bus contactor interposed between the high-voltage bus and the battery charger, which is bus contactor configured to provide a first substantial electrical isolation between the battery charger and the high-voltage bus during a charging period of the battery module.

Abstract: In order to provide a modular arrangement, an inverter for an electric traction motor used to drive an automotive vehicle is positioned in proximity with the traction motor. The inverter is located within a compartment adjacent to one end of the electric traction motor and is cooled in a closed system by spraying a liquid coolant directly onto the inverter. The liquid coolant absorbs heat from the inverter and is cooled by a heat exchange arrangement comprising a reservoir with pipes carrying a second coolant from the radiator of the automotive vehicle. In a preferred embodiment, the coolant is collected from the inverter in an annular reservoir that is integral with the compartment containing the inverter. In accordance with one embodiment of the cooling arrangement, heat from the inverter vaporizes the liquid coolant by absorbing heat from the inverter during a phase change from a liquid to a vapor.

Abstract: Methods and apparatus are provided for charging a high-voltage battery of a hybrid electric vehicle. The high-voltage battery charging apparatus comprises a battery charger configured to provide electrical energy, a battery module configured to store the electrical energy provided by the battery charger, and a high-voltage bus coupled to the battery charger and the battery module, which is configured to transmit the electrical energy from the battery charger and battery module to the electrical system of the hybrid electric vehicle. In addition, the high-voltage battery charging apparatus comprises a bus contactor interposed between the high-voltage bus and the battery charger, which is bus contactor configured to provide a first substantial electrical isolation between the battery charger and the high-voltage bus during a charging period of the battery module.