Abstract: A bearing carrier may include a hub defining a bearing surface. A rotating assembly may include the bearing carrier and a bearing coupled to the bearing surface. The bearing carrier may also include an annular lip extending from a flange of the hub. The rotating assembly may also include a pump coupler coupled to the annular lip of the bearing carrier. A generator may include the rotating assembly and an oil-pump coupled to the oil-pump coupler. The rotating assembly may also include an electromagnetic rotor. The generator may include an electromagnetic stator which generates electricity in response to a magnetic field induced by the electromagnetic rotor of the rotating assembly.

Abstract: A metal gasket includes a metal plate formed as a continuous metal ring, a continuous metal bead formed into the continuous metal ring, and a continuous edge bond gasket fixed to the continuous metal ring. In an example embodiment, the continuous edge bond gasket is fixed to an inner edge of the continuous metal ring. In an example embodiment, the continuous edge bond gasket is an elastomeric seal. The disclosure also relates to a generator module including a housing, a high-voltage header, a junction box, and the metal gasket. The gasket is arranged to seal the high voltage header to the housing, and the junction box to the housing.

Abstract: An electromagnetic compatible enclosure, for example, a junction box of an electric or hybrid vehicle, having a housing having a cavity, a cover secured to the housing with a plurality of fasteners, the cover enclosing the cavity. The cover includes a metal plate and a polymer body fixed to the metal plate.

Abstract: A generator for a hybrid vehicle includes a housing including an end cover having an axially extending center support, a stator supported in the housing, a rotor assembly supported for rotation in the housing relative to the stator, and a center shaft coaxial with the rotor assembly. The center shaft is supported for rotation at a first axial position by the center support of the end cover, the center shaft extends axially from the center support and supports the rotor assembly at a second axial position, and the rotor assembly is supported at the first axial side of the generator by a support plate extending radially between a carrier of the rotor assembly and the center support of the housing.

Abstract: An emotor mounting arrangement for an internal combustion engine is provided, including an emotor having a rotor that is rotatably mounted and a stator that is fixed relative to the engine. A hub is connected to the rotor, with the hub including a pilot extension that is adapted to be supported in an end of a crankshaft of the internal combustion engine. A drive plate is connected to and extends radially from the hub, and the drive plate includes connector openings that are adapted for connecting the drive plate to a flex plate connected to the crankshaft. The hub can b integrally formed with a rotor carrier, or the hub can be assembled from stamped sheet metal parts.

Abstract: An electric motor assembly including a housing having an internal surface including an annular array of positioning features including at least one deformable stake extending in an axial direction, and a resolver stator configured to be mounted within the housing and including a corresponding annular array of radially extending alignment features, wherein each deformable stake is configured to be deformed into contact with one of the radially extending alignment features to constrain motion of the resolver stator relative to the housing. Assemblies including corresponding alignment and retention features for maintaining positional relationships between mounted components without the need for separate fasteners.

Abstract: End plates may be segmented into annular segments. The annular segments may be joined using interlocking joints to form the end plates. The annular segments may also include radial grooves for channeling fluid radially outwards from the end plates. The end plates may be a non-ferromagnetic metal. A rotor assembly may include a pair of the end plates on opposing sides of a rotor to magnetically isolate permanent magnets within the rotor. The end plates and the rotor may be clamped to a rotor carrier hub of the rotor assembly via a clamp ring. An electric motor may include the rotor assembly for transmitting torque.

Abstract: A generator module for a vehicle includes a housing arranged for fixing to a combustion engine, a stator fixed in the housing, a rotor, rotatable within the stator and arranged for driving connection with the combustion engine, and a damper arranged in a torque path between the combustion engine and the rotor for damping torsional vibrations from the combustion engine.

Abstract: A bearing carrier may include a hub defining a bearing surface. A rotating assembly may include the bearing carrier and a bearing coupled to the bearing surface. The bearing carrier may also include an annular lip extending from a flange of the hub. The rotating assembly may also include a pump coupler coupled to the annular lip of the bearing carrier. A generator may include the rotating assembly and an oil-pump coupled to the oil-pump coupler. The rotating assembly may also include an electromagnetic rotor. The generator may include an electromagnetic stator which generates electricity in response to a magnetic field induced by the electromagnetic rotor of the rotating assembly.

Abstract: A vehicle includes a combustion engine, a first axle assembly rotationally connected to a first pair of driving wheels, and a vehicle generator module. The vehicle generator module includes a rotor rotationally connected to the combustion engine, a stator circumscribing the rotor and arranged for generating an electrical power when the rotor is rotated by the combustion engine, and a clutch for selectively rotationally connecting the combustion engine to the first axle assembly. In some example embodiment, the vehicle also includes a transmission arranged in a torque path between the clutch and the first axle assembly. In an example embodiment, the transmission is a single speed transmission.

Abstract: A hybrid module is provided that includes a water jacket and an oil reservoir. The water jacket can be configured to both directly provide a heat exchanger feature for a stator as well as the oil reservoir. Oil within the oil reservoir can be configured to be sprayed towards the stator at the same time that the water jacket is cooling the stator. This configuration provides an improved cooling effect for the stator.

Abstract: A radially compliant connection includes an axis, a first plate with a first connection portion, a second plate with a second connection portion, an intermediate plate with third and fourth connection portions, a first flexible element fixed to the first connection portion and to the third connection portion, and a second flexible element fixed to the second connection portion and to the fourth connection portion. In some example embodiments, the first connection portion has a radially inner surface with a first radius, and the second connection portion has a first radially outer surface with a second radius, less than the first radius. In an example embodiment, the third connection portion has a second radially outer surface with a third radius, equal to the second radius, or the fourth connection portion has a third radially outer surface with a fourth radius, equal to the second radius.

Abstract: A high-voltage connector having a connector body, at least one conductor supported in the connector body, and a seal member surrounding the at least one conductor at an interface of the connector body and the at least one conductor. A seal retainer secures the seal to prevent removal of the seal.

Abstract: A generator module for a vehicle includes a housing with a first conical surface, a rotor assembly with a second conical surface, aligned with the first conical surface, and a spring arranged to push the second conical surface into contact with the first conical surface. In an example embodiment, the first conical surface or the second conical surface includes a plastic surface or a friction paper surface. In an example embodiment, the rotor assembly is axially displaceable within the housing to compress the spring and move the second conical surface away from the first conical surface.

Abstract: A generator module for a vehicle includes a housing with a first conical surface, a rotor assembly with a second conical surface, aligned with the first conical surface, and a spring arranged to push the second conical surface into contact with the first conical surface. In an example embodiment, the first conical surface or the second conical surface includes a plastic surface or a friction paper surface. In an example embodiment, the rotor assembly is axially displaceable within the housing to compress the spring and move the second conical surface away from the first conical surface.

Abstract: A cooling crescent for a hybrid module includes a first half section and a second half section. The first half section has a radially outer inlet orifice and a plurality of circumferentially disposed radially inner outlet orifices. The second half section is sealed to the first half section to form a narrow channel hydraulically connected to the radially outer inlet orifice, and a circumferentially extending channel hydraulically connected to the narrow channel and the plurality of circumferentially disposed radially inner outlet orifices. In some example embodiments, the first half section or the second half section comprises a plurality of axially extending tabs with respective orifices for fixing the cooling crescent to a housing of the hybrid module. In an embodiment, the plurality of axially extending tabs are configured to be adjustable to vary a respective height of the tabs to accommodate for e-motor stators of varying sizes.

Abstract: A generator module includes a housing arranged for mounting to a rear face of an internal combustion engine, a generator stator fixed in the housing, a generator rotor arranged radially inside of the generator stator, and a bearing arranged to support a radial inside of the generator rotor on the housing. The generator rotor may include a rotor carrier and a plurality of stacked plates secured to the rotor carrier. The bearing may be at least partially radially aligned with the plurality of stacked plates.

Abstract: A starter-generator module for a vehicle includes a bulkhead wall, a module housing fixed to the bulkhead wall, an e-motor stator fixed to the module housing, an e-motor rotor disposed radially inside of the e-motor stator, and a power electronics unit fixed to the module housing. The module housing has a first opening and the power electronics unit covers the first opening. The e-motor rotor has a rotor carrier arranged for fixing to a crankshaft of the internal combustion engine. In an example embodiment, the rotor carrier includes holes arranged for receiving respective fasteners for fixing the rotor carrier to an engine crankshaft, and a bolt circle diameter of the holes is less than an inside diameter of the first opening. In an example embodiment, the rotor carrier is fixed to a crankshaft by a bolt, and the first opening is arranged for receiving a tool to secure the bolt.

Abstract: A hybrid module is provided that includes a water jacket and an oil reservoir. The water jacket can be configured to both directly provide a heat exchanger feature for a stator as well as the oil reservoir. Oil within the oil reservoir can be configured to be sprayed towards the stator at the same time that the water jacket is cooling the stator. This configuration provides an improved cooling effect for the stator.

Abstract: A generator module includes a housing arranged for mounting to a rear face of an internal combustion engine, a generator stator fixed in the housing, a generator rotor arranged radially inside of the generator stator, and a bearing arranged to support a radial inside of the generator rotor on the housing. The generator rotor may include a rotor carrier and a plurality of stacked plates secured to the rotor carrier. The bearing may be at least partially radially aligned with the plurality of stacked plates.