Patents by Inventor Michael D. Bradfield

Michael D. Bradfield has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 10605218
    Abstract: A number of variations may include a solenoid assembly comprising: a shaft; a pinion-plunger operatively attached to the shaft and having a first end comprising a plurality of teeth; a plurality of iron cores surrounding at least a portion of the pinion-plunger and the shaft; at least one solenoid coil winding and at least one spool surrounding each of the plurality of iron cores; a stop adjacent a first end of the plurality of iron cores; a guide adjacent a second end of the plurality of iron cores opposite of the stop; a biasing member in operative communication with the first end the pinion-plunger; and wherein the solenoid assembly is constructed and arranged so that when the solenoid assembly is activated the pinion-plunger is magnetically drawn toward the stop.
    Type: Grant
    Filed: February 10, 2017
    Date of Patent: March 31, 2020
    Assignee: BORGWARNER INC.
    Inventor: Michael D. Bradfield
  • Publication number: 20190363592
    Abstract: A pole piece (106) for a rotor (100) of a rotary electric machine (20) includes a hub portion (104) and a plurality of pole segments (106) distributed evenly about the hub portion (104). The pole segments each have a base (116) that is connected to the hub portion (104) and a tip (118) that is disposed axially opposite the base (116) along an axis (60) of the pole piece (106). Each pole segment (106) defines circumferentially opposite side surfaces (120, 122) that extend between the base (116) and the tip (118). Each pole segment (106) also defines radially opposite outer and inner surfaces (124, 126) that extend between the side surfaces (120, 122). A groove is recessed in the side surfaces (120, 122) of each pole segment (106). A radially innermost portion (136) of the groove (130, 132) is arranged proximate to the radially outer surface.
    Type: Application
    Filed: May 23, 2019
    Publication date: November 28, 2019
    Inventor: Michael D. Bradfield
  • Patent number: 10389211
    Abstract: An electronic package adapted for connection to a rear frame member of an electric machine. The electronic package includes a cooling tower having first and second axial ends. The cooling tower includes a metallic wall defining radially inner and outer wall surfaces and extending about the package central axis. The radially inner wall surface defines an axially extending air passage through the cooling tower with an inlet proximate the first axial end. Spaced metallic ribs are in conductive thermal communication with the radially inner wall surface traverse and the air passage. Power electronics devices are attached in conductive thermal communication to the radially outer wall surface. The cooling tower provides a heat sink for the power electronics devices with a primary cooling path for each of the power electronics device extending radially inwardly to the cooling tower. An electric machine including such an electronic package is also disclosed.
    Type: Grant
    Filed: October 7, 2015
    Date of Patent: August 20, 2019
    Assignee: BORGWARNER INC.
    Inventor: Michael D. Bradfield
  • Patent number: 10332822
    Abstract: An electronic package connectable to an electric machine includes a cooling tower having a metallic wall with a radially outer wall surface. The radially outer wall surface includes discrete, radially outwardly projecting pedestals. The planar pedestal mounting surfaces are parallel with the central axis such that the radial distance between the axis and the radially outer wall surface is greater within the periphery than outside the periphery. Power modules are mounted to the pedestals. Each power module includes a base in thermal contact with a pedestal mounting surface and an opposing interior surface in thermal communication with a MOSFET power electronics device. A cover plate is spaced from the base interior surface. A dielectric housing member surrounds the MOSFET power electronics devices. An electrical connection terminal is disposed outside the periphery of each module. An electric machine including such an electronic package is also disclosed.
    Type: Grant
    Filed: August 8, 2018
    Date of Patent: June 25, 2019
    Assignee: BORGWARNER INC.
    Inventor: Michael D. Bradfield
  • Publication number: 20190140498
    Abstract: A claw pole member for an electric machine including a plurality of claw pole segments. Each of the plurality of claw pole segments includes a radial projecting member, an axial outer surface extending to a cantilevered end portion, and an axial inner surface extending axially outwardly of the radial projecting member to a cantilevered end section. A first side surface extends between the axial outer surface and the axial inner surface from the radial projecting member to the cantilevered end portion and the cantilevered end section, and a second side surface extends between the axial outer surface and the axial inner surface from the radial projecting member to the cantilevered end portion and the cantilevered end section. The first and second side surfaces define a taper of the claw pole segment. Each of the first and second side surfaces includes a recessed portion that extends into the claw pole segment.
    Type: Application
    Filed: November 1, 2018
    Publication date: May 9, 2019
    Applicant: BorgWarner Inc.
    Inventor: Michael D. Bradfield
  • Patent number: 10250104
    Abstract: An electronic package adapted for connection to a rear frame member of an electric machine. The electronic package includes a support structure having opposite first and second axial ends spaced along a package central axis. A plurality of power electronics devices connected to the support structure and electronic control circuitry is carried by the support structure. The electronic control circuitry is substantially surrounded by and operatively connected to the power electronics devices. The control circuitry includes circuit board material having opposing substantially parallel sides, wherein the control circuitry comprises first and second control circuit portions respectively disposed on separate first and second circuit board material portions wherein the first and second circuit board material portions substantially coextend with distinct first and second imaginary planes, respectively. An electric machine employing such an electronic package is also disclosed.
    Type: Grant
    Filed: October 7, 2015
    Date of Patent: April 2, 2019
    Assignee: BORGWARNER INC.
    Inventor: Michael D. Bradfield
  • Patent number: 10250100
    Abstract: Embodiments of the invention provide a starter that includes a motor with an armature that is coupled to a pinion. In some embodiments, the starter can include a main field coil that can be configured and arranged to produce a main magnetic field flux. Some embodiments include at least one auxiliary flux assembly arranged in close proximity with the main field coil and electrically disconnected from it. In some embodiments, a control system can operatively power the main field coil to produce a magnetic field flux. In some embodiments, the at least one auxiliary flux assembly can provide a supplementary field flux adding to the main magnetic field flux that interacts with the armature.
    Type: Grant
    Filed: March 15, 2013
    Date of Patent: April 2, 2019
    Assignees: REMY TECHNOLOGIES, L.L.C., REMY POWER PRODUCTS, L.L.C.
    Inventor: Michael D. Bradfield
  • Patent number: 10164504
    Abstract: A power module for an electric machine. The power module includes a thermally conductive base having opposite first and second surfaces. The first surface is adapted for mounting the power module in conductive thermal communication with a heat sink. A MOSFET superposes the base second surface and is in conductive thermal communication with the base. A MOSFET driver superposes the base second surface and is operatively connected to the MOSFET. The transference from the power module of heat generated by the MOSFET and the MOSFET driver from the power module is directed along a primary cooling path to the heat sink through the base and a secondary cooling path to ambient air. The primary and secondary cooling paths are separate from each other. An electronics package and an electric machine including a power module are also disclosed.
    Type: Grant
    Filed: October 7, 2015
    Date of Patent: December 25, 2018
    Assignee: BORGWARNER INC.
    Inventor: Michael D. Bradfield
  • Publication number: 20180350720
    Abstract: An electronic package connectable to an electric machine includes a cooling tower having a metallic wall with a radially outer wall surface. The radially outer wall surface includes discrete, radially outwardly projecting pedestals. The planar pedestal mounting surfaces are parallel with the central axis such that the radial distance between the axis and the radially outer wall surface is greater within the periphery than outside the periphery. Power modules are mounted to the pedestals. Each power module includes a base in thermal contact with a pedestal mounting surface and an opposing interior surface in thermal communication with a MOSFET power electronics device. A cover plate is spaced from the base interior surface. A dielectric housing member surrounds the MOSFET power electronics devices. An electrical connection terminal is disposed outside the periphery of each module. An electric machine including such an electronic package is also disclosed.
    Type: Application
    Filed: August 8, 2018
    Publication date: December 6, 2018
    Inventor: Michael D. Bradfield
  • Patent number: 10090735
    Abstract: An electronic package connectable to an electric machine. The electronic package includes a support structure with a first axial end engaged with the electric machine. The support structure circumscribes the central axis and defines radially inner and outer wall surfaces. Power modules are disposed on and circumferentially distributed about the radially outer wall surface and include a power electronics device. Each module includes a phase terminal coupled with the power electronics device and disposed radially outwardly of the radially outer wall surface. The support structure defines a plurality of voids extending between the radially inner and outer wall surfaces. Each of the power modules are positioned proximate a separate one of the voids. Each void has a phase lead extending therethrough. Each phase lead is connected to a phase terminal and conductively couples it with a stator winding. An electric machine having an electronic package is also disclosed.
    Type: Grant
    Filed: October 6, 2015
    Date of Patent: October 2, 2018
    Assignee: BORGWARNER INC.
    Inventor: Michael D. Bradfield
  • Patent number: 10090727
    Abstract: An electronic package adapted for connection to a rear frame member of an electric machine. The electronic package includes a cooling tower having first and second axial ends and a central axis. The cooling tower includes a metallic first wall extending about the central axis and defining radially inner and outer first wall surfaces. An axially extending air flow passage extends through the cooling tower. Spaced metallic ribs traverse the air flow space and are in conductive thermal communication with the radially inner first wall surface. A plurality of circumferentially distributed power electronics devices are in conductive thermal communication with the cooling tower and secured to the radially outer first wall surface to thereby provide a heat sink for the power electronics devices. Electronic control circuitry is operatively connected to and substantially surrounded by the power electronics devices. An electric machine with such an electronic package is also disclosed.
    Type: Grant
    Filed: October 6, 2015
    Date of Patent: October 2, 2018
    Assignee: BORGWARNER INC.
    Inventor: Michael D. Bradfield
  • Patent number: 10074592
    Abstract: An electronic package connectable to an electric machine includes a cooling tower having a metallic wall with a radially outer wall surface. The radially outer wall surface includes discrete, radially outwardly projecting pedestals. The planar pedestal mounting surfaces are parallel with the central axis such that the radial distance between the axis and the radially outer wall surface is greater within the periphery than outside the periphery. Power modules are mounted to the pedestals. Each power module includes a base in thermal contact with a pedestal mounting surface and an opposing interior surface in thermal communication with a MOSFET power electronics device. A cover plate is spaced from the base interior surface. A dielectric housing member surrounds the MOSFET power electronics devices. An electrical connection terminal is disposed outside the periphery of each module. An electric machine including such an electronic package is also disclosed.
    Type: Grant
    Filed: October 6, 2015
    Date of Patent: September 11, 2018
    Assignee: BORGWARNER INC.
    Inventor: Michael D. Bradfield
  • Patent number: 9960654
    Abstract: An electronic package adapted for connection to a rear frame member of an electric machine of liquid and/or air-cooled type. The electronic package includes a cooling tower having opposite first and second axial ends spaced along a package central axis. The cooling tower includes a metallic wall extending about the package central axis to define a radially outer wall surface. The cooling tower is at ground potential and defines a heat sink. The electronic package also includes a plurality of power modules mounted in conductive thermal communication to the cooling tower at positions on the radially outer wall surface. Heat transference to the cooling tower from each power module occurs along a respective primary cooling path. Transference along the primary cooling paths of heat from the cooling tower includes thermal convection to air and/or liquid. An electric machine of liquid and/or air-cooled type including an electronic package is also disclosed.
    Type: Grant
    Filed: October 7, 2015
    Date of Patent: May 1, 2018
    Assignee: BORGWARNER INC.
    Inventor: Michael D. Bradfield
  • Publication number: 20170152828
    Abstract: A number of variations may include a solenoid assembly comprising: a shaft; a pinion-plunger operatively attached to the shaft and having a first end comprising a plurality of teeth; a plurality of iron cores surrounding at least a portion of the pinion-plunger and the shaft; at least one solenoid coil winding and at least one spool surrounding each of the plurality of iron cores; a stop adjacent a first end of the plurality of iron cores; a guide adjacent a second end of the plurality of iron cores opposite of the stop; a biasing member in operative communication with the first end the pinion-plunger; and wherein the solenoid assembly is constructed and arranged so that when the solenoid assembly is activated the pinion-plunger is magnetically drawn toward the stop.
    Type: Application
    Filed: February 10, 2017
    Publication date: June 1, 2017
    Inventor: MICHAEL D. BRADFIELD
  • Patent number: 9577501
    Abstract: A rotor for a rotary electric machine, the rotor including first and second pole pieces each having a respective magnetic hub arranged for rotation about an axis along which they are spaced. Pluralities of magnetic first and second pole fingers are spaced from each other and extend between the hubs. Each pole finger has a proximal end connected to its respective hub, and an axially opposite distal end. The first and second pole fingers circumferentially alternate about the axis, and each pole finger has a respective radially inner surface defining a cavity that extends axially from the distal end to a cavity terminus. Relative to each pole finger, at a respective axial position between the distal end and the cavity terminus the radial distance between the axis and the radially inner surface is substantially greater inside of the cavity than outside of the cavity.
    Type: Grant
    Filed: November 20, 2013
    Date of Patent: February 21, 2017
    Assignee: Remy Technologies, LLC
    Inventor: Michael D. Bradfield
  • Patent number: 9441601
    Abstract: A vehicle starter motor arrangement comprises a battery, a first vehicle starter motor including a first pinion and a second vehicle starter motor including a second pinion. The first vehicle starter motor is connected in series to the battery and the second vehicle starter motor is connected in series to the first vehicle starter motor. Accordingly, the battery, the first vehicle starter motor, and the second vehicle starter motor are all connected in series. The first pinion gear and the second pinion gear are configured to engage an engine ring gear when electrical current flows through the first vehicle starter motor and the second vehicle starter motor.
    Type: Grant
    Filed: June 16, 2014
    Date of Patent: September 13, 2016
    Assignee: REMY TECHNOLOGIES, LLC
    Inventors: Michael D. Bradfield, Attila Nagy
  • Patent number: 9444306
    Abstract: A variable flux electric starter motor includes a frame, an armature rotatably mounted within the frame, and a primary field mounted to the frame. The primary field includes a plurality of primary windings electrically connected one to another. A relay is electrically coupled to at least one of the plurality of poles. A supplemental field is mounted to the frame. The supplemental field includes a supplemental winding electrically connected in parallel to the plurality of primary windings.
    Type: Grant
    Filed: May 25, 2012
    Date of Patent: September 13, 2016
    Assignee: REMY TECHNOLOGIES, L.L.C.
    Inventor: Michael D. Bradfield
  • Patent number: 9429131
    Abstract: A method for controlling an engine starter system including a starter capable of being controlled by an electronic control unit and having an electric motor and a pinion coupled together for transferring rotational torque from the motor to the pinion when the motor is activated; controlling activation of the motor with an electronic control unit output motor signal in response to an engine speed input signal; determining the pinion speed in an open loop manner based solely on the time since activation of the motor and the voltage applied to the motor; and selectively moving the pinion between a retracted state and an extended state in response to an electronic control unit output pinion signal, whereby the starter is capable of selectively engaging an engine for cranking the engine. Also, a starter system that facilitates this method.
    Type: Grant
    Filed: January 24, 2014
    Date of Patent: August 30, 2016
    Assignee: Remy Technologies, LLC
    Inventor: Michael D. Bradfield
  • Patent number: 9424972
    Abstract: A solenoid for a vehicle starter includes at least one coil with a passage extending through the coil in an axial direction. The solenoid further includes a plunger configured to move in the axial direction within the passage. The plunger includes a cylindrical outer surface with a substantially uniform diameter and a circumferential notch. The cylindrical outer surface includes a first portion with a first diameter on one side of the circumferential notch, and a second portion with the first diameter on an opposite side of the circumferential notch. The circumferential notch includes a portion with a second diameter that is less than the first diameter.
    Type: Grant
    Filed: May 1, 2014
    Date of Patent: August 23, 2016
    Assignee: Remy Technologies, LLC
    Inventors: Stephen P. Santichen, Michael D. Bradfield
  • Publication number: 20160105068
    Abstract: An electronic package adapted for connection to a rear frame member of an electric machine of liquid and/or air-cooled type. The electronic package includes a cooling tower having opposite first and second axial ends spaced along a package central axis. The cooling tower includes a metallic wall extending about the package central axis to define a radially outer wall surface. The cooling tower is at ground potential and defines a heat sink. The electronic package also includes a plurality of power modules mounted in conductive thermal communication to the cooling tower at positions on the radially outer wall surface. Heat transference to the cooling tower from each power module occurs along a respective primary cooling path. Transference along the primary cooling paths of heat from the cooling tower includes thermal convection to air and/or liquid. An electric machine of liquid and/or air-cooled type including an electronic package is also disclosed.
    Type: Application
    Filed: October 7, 2015
    Publication date: April 14, 2016
    Inventor: Michael D. Bradfield