Abstract: A rotor for an electric machine includes a rotor assembly having an outer surface and including a plurality of poles with permanent magnets. A solid layer is formed on the outer surface of the rotor assembly and has an outer surface with a first coefficient of friction that is lower than a second coefficient of friction of the outer surface of the rotor assembly. The rotor includes an outer sleeve. The rotor assembly is press-fit into the outer sleeve.

Abstract: An adhesive-reinforced rotor for a rotary electric machine includes rotor lamination layers (“rotor lams”) having axial inner surfaces collectively defining rotor openings through the rotor lams. The rotor also includes reinforcement blocks disposed within a respective one of the rotor openings. A polymer primer/adhesive layer of the rotor having a bond line thickness of less than 1 mm is disposed between the one or more reinforcement blocks and the axial inner surfaces of the rotor lams. The reinforcement blocks and the primer/adhesive layer each have a tensile strength of at least 50 MPa. A modulus of elasticity of the reinforcement blocks is at least three times greater than that of the materials of the polymer primer/adhesive layer. A method of constructing an adhesive-reinforced rotor is also described herein.

Abstract: A rotor for an electric machine includes a rotor assembly having an outer surface and including a plurality of poles with permanent magnets. A solid layer is formed on the outer surface of the rotor assembly and has an outer surface with a first coefficient of friction that is lower than a second coefficient of friction of the outer surface of the rotor assembly. The rotor includes an outer sleeve. The rotor assembly is press-fit into the outer sleeve.

Abstract: A rotor assembly for a permanent magnet motor includes a first assembly including a first plurality of laminations and a second assembly including a second plurality of laminations. The first assembly is located radially inside of the second assembly. The first assembly and the second assembly define a first opening therebetween. First and second permanent magnets are located in the first opening. Polymeric material surrounds the first and second permanent magnets in the first opening. An outer layer surrounds the rotor assembly.

Abstract: A rotor for an electric machine includes a rotor body formed from a plurality of stacked laminations defining a first axial end and an opposing second axial end. Each of the plurality of stacked laminations includes a plurality of openings that are aligned so as to define a plurality of passages through the rotor body. A plurality of reinforcement elements extend through the plurality of stacked laminations. Each of the plurality of reinforcement elements is arranged in a corresponding one of the plurality of passages and includes a first end portion and a second end portion. The first end portion and the second end portion of select ones of the plurality of reinforcement elements extend outwardly of the first axial end and the second axial end.

Abstract: Methods for manufacturing a pouch-type battery cell include disposing one or more electrode pairs between a first aluminum pouch layer and a second aluminum pouch layer, sealing the first pouch layer and the second pouch layer to form a peripheral seal joining the first pouch layer and the second pouch layer to form a pouch with an outer edge encasing the anode and the cathode, applying a photocatalytic polymer coating precursor to the outer edge of the pouch, and photo-curing the photocatalytic polymer coating precursor to form a conformal edge coating. The photocatalytic polymer coating precursor includes one or more photo-initiators, one or more acrylates, and one or more polyamines. The polyamines can include tertiary amines including ?-CH functional groups, diamines represented by the formula H2N—R—NH2, wherein R represents saturated and unsaturated aliphatic moieties, and N,N?-(2,2-dimethylpropylidene) hexamethylenediamine.

Abstract: Presented are electronic power module assemblies with direct-cooling vapor chamber systems, methods for making/using such power module assemblies, and vehicles equipped with such power module assemblies. A power module assembly includes an outer housing with an internal coolant chamber that circulates therethrough a coolant fluid. A power semiconductor switching device is mounted to the module's housing, separated from the coolant chamber and isolated from the coolant fluid. The power device selectively modifies electric current transmitted between a power source and an electrical load. A two-phase, heat-spreading vapor chamber device includes an outer casing with a casing segment that is mounted to the module housing, fluidly sealed to the internal coolant chamber and exposed to the coolant fluid.

Abstract: An adhesive-reinforced rotor for a rotary electric machine includes rotor lamination layers (“rotor lams”) having axial inner surfaces collectively defining rotor openings through the rotor lams. The rotor also includes reinforcement blocks disposed within a respective one of the rotor openings. A polymer primer/adhesive layer of the rotor having a bond line thickness of less than 1 mm is disposed between the one or more reinforcement blocks and the axial inner surfaces of the rotor lams. The reinforcement blocks and the primer/adhesive layer each have a tensile strength of at least 50 MPa. A modulus of elasticity of the reinforcement blocks is at least three times greater than that of the materials of the polymer primer/adhesive layer. A method of constructing an adhesive-reinforced rotor is also described herein.

Abstract: Presented are electronic power module assemblies with direct-cooling heat pipe systems, methods for making/using such power module assemblies, and vehicles equipped with such power module assemblies. A power module assembly includes an outer housing with an internal coolant chamber that circulates therethrough a coolant fluid. A sidewall of the module's housing defines therethrough multiple coolant windows that fluidly connect to the coolant chamber. A power semiconductor switching device is mounted to the module housing, fluidly sealed to a first coolant window with the power device's inboard surface exposed to the coolant fluid. The power device is operable to modify electric current transmitted between a power source and an electrical load. A heat pipe with an outer casing has a first casing segment thereof mounted to an outboard surface of the power device, and a second casing segment fluidly sealed to a second coolant window and exposed to the coolant fluid.

Abstract: Presented are electronic power module assemblies with direct-cooling vapor chamber systems, methods for making/using such power module assemblies, and vehicles equipped with such power module assemblies. A power module assembly includes an outer housing with an internal coolant chamber that circulates therethrough a coolant fluid. A power semiconductor switching device is mounted to the module's housing, separated from the coolant chamber and isolated from the coolant fluid. The power device selectively modifies electric current transmitted between a power source and an electrical load. A two-phase, heat-spreading vapor chamber device includes an outer casing with a casing segment that is mounted to the module housing, fluidly sealed to the internal coolant chamber and exposed to the coolant fluid.

Abstract: A corrosion-resistant workpiece is provided. The corrosion-resistant workpiece includes a matrix including a valve metal or an alloy including a valve metal; an oxide layer formed on the matrix, the oxide layer including a plurality of pores, wherein each pore of the plurality has a pore volume; and a polymeric composition disposed within at least a portion of the plurality of pores, wherein greater than or equal to about 70% of the pore volume for each pore having the polymeric composition disposed therein is filled with the polymeric composition. A method of fabricating the corrosion-resistant workpiece is also provided.

Abstract: Presented are electronic power module assemblies with direct-cooling heat pipe systems, methods for making/using such power module assemblies, and vehicles equipped with such power module assemblies. A power module assembly includes an outer housing with an internal coolant chamber that circulates therethrough a coolant fluid. A sidewall of the module's housing defines therethrough multiple coolant windows that fluidly connect to the coolant chamber. A power semiconductor switching device is mounted to the module housing, fluidly sealed to a first coolant window with the power device's inboard surface exposed to the coolant fluid. The power device is operable to modify electric current transmitted between a power source and an electrical load. A heat pipe with an outer casing has a first casing segment thereof mounted to an outboard surface of the power device, and a second casing segment fluidly sealed to a second coolant window and exposed to the coolant fluid.

Abstract: Methods for manufacturing a pouch-type battery cell include disposing one or more electrode pairs between a first aluminum pouch layer and a second aluminum pouch layer, sealing the first pouch layer and the second pouch layer to form a peripheral seal joining the first pouch layer and the second pouch layer to form a pouch with an outer edge encasing the anode and the cathode, applying a photocatalytic polymer coating precursor to the outer edge of the pouch, and photo-curing the photocatalytic polymer coating precursor to form a conformal edge coating. The photocatalytic polymer coating precursor includes one or more photo-initiators, one or more acrylates, and one or more polyamines. The polyamines can include tertiary amines including ?-CH functional groups, diamines represented by the formula H2N—R—NH2, wherein R represents saturated and unsaturated aliphatic moieties, and N,N?-(2,2-dimethylpropylidene) hexamethylenediamine.

Abstract: An example of a thermal composite includes a substrate, a primer layer, a first adhesive layer, a blanket layer, a second adhesive layer, and a metal layer. The blanket layer includes basalt fibers or glass fibers. The thermal composite may be incorporated into a battery pack as a battery enclosure.

Abstract: A lap belt pretensioner for a lap belt configured to secure an occupant of a vehicle seat includes a pyrotechnic device. The pyrotechnic device is configured to generate a force directed to tension the lap belt around the occupant and emit an exhaust gas including particulates at high pressure and high temperature as a byproduct of the generated force. The lap belt pretensioner also includes a housing configured to retain the pyrotechnic device and defining an exhaust passage configured to expel the exhaust gas from the lap belt pretensioner. The lap belt pretensioner additionally includes a shield arranged over the exhaust passage and configured to collect and/or deflect the emitted particulates and dissipate heat energy thereof. A vehicle having the vehicle seat mounted to the vehicle structure and employing the seatbelt system is also provided.

Abstract: A lap belt pretensioner for a lap belt configured to secure an occupant of a vehicle seat includes a pyrotechnic device. The pyrotechnic device is configured to generate a force directed to tension the lap belt around the occupant and emit an exhaust gas including particulates at high pressure and high temperature as a byproduct of the generated force. The lap belt pretensioner also includes a housing configured to retain the pyrotechnic device and defining an exhaust passage configured to expel the exhaust gas from the lap belt pretensioner. The lap belt pretensioner additionally includes a shield arranged over the exhaust passage and configured to collect and/or deflect the emitted particulates and dissipate heat energy thereof. A vehicle having the vehicle seat mounted to the vehicle structure and employing the seatbelt system is also provided.

Abstract: An example of a thermal composite includes a substrate, a primer layer, a first adhesive layer, a blanket layer, a second adhesive layer, and a metal layer. The blanket layer includes basalt fibers or glass fibers. The thermal composite may be incorporated into a battery pack as a battery enclosure.

Abstract: A battery enclosure comprising a support and a cover fabricated from a thermoset or thermoplastic polymer reinforced by at least a woven fabric reinforcement is described. In an embodiment the reinforcement is a woven glass fabric.

Abstract: A battery enclosure comprising a support and a cover fabricated from a thermoset or thermoplastic polymer reinforced by at least a woven fabric reinforcement is described. In an embodiment the reinforcement is a woven glass fabric.

Abstract: A cover for a high voltage vehicle battery is disclosed that is made of a light weight, non-conductive thermoset plastic composite, such as a polyester resin matrix, and includes an EMI/RFI shield. In one embodiment, the EMI/RFI shield is a Faraday cage including a ferrous mesh that is molded into the thermoset plastic composite so that it is completely encapsulated therein. In another embodiment, the EMI/RFI shield is an acrylic polymer coating including nickel plated copper flakes formed on an outside surface of the thermoset plastic composite.