Abstract: This disclosure describes liquid cooled electrical connectors for connecting components of electrified vehicles or components of any other type of power connection/power transfer system. Exemplary electrical connectors include integrated cooling circuits that employ heat exchanger channels for circulating a fluid for convectively cooling bus bars of the connector.

Abstract: A power inductor includes a housing and a magnetic core disposed in the housing. The core includes a first segment and a second segment spaced apart from each other to define a gap. The first and second segments are supported in the housing such that they are movable relative to each other to increase and decrease the size of the gap. A passive actuator is disposed in the housing and is configured to move the second segment relative to the first segment to increase and decrease the size of the gap. The passive actuator includes a shape-memory alloy configured to expand as temperature of the inductor increases to urge the first and second segments apart to increase the gap and to contract as the temperature decreases so that the first and second segments move towards each other to decrease the gap.

Abstract: An electric machine for an electrified vehicle includes a stator core configured to receive a plurality of windings and an overmolded midsection formed about the stator core. The midsection also defines a first interlocking feature disposed near an end face of the stator core. The electric machine also includes an end cap defining at least a portion of a coolant channel and a second interlocking feature configured to engage the first interlocking feature and create a fluid seal to retain fluid within the coolant channel. The coolant channel is further arranged to encase end portions of the plurality of windings and direct circulating coolant across the end portions.

Abstract: A power inductor includes a housing and a magnetic core disposed in the housing. The core includes a first segment and a second segment spaced apart from each other to define a gap. The first and second segments are supported in the housing such that the they are movable relative to each other to increase and decrease the size of the gap. A fluid having a positive thermal expansion coefficient is disposed in the housing such that expansion and contraction of the fluid due to change in temperature increases and decreases the gap, respectively.

Abstract: A charge system includes a charge cable containing a coolant to be circulated therethrough, and wires submersed and in direct contact with the coolant. The charge system also includes a controller that alters a pressure of the coolant within the charge cable to maintain nucleate boiling of the coolant.

Abstract: This disclosure describes liquid cooled electrical connectors for connecting components of electrified vehicles or components of any other type of power connection/power transfer system. Exemplary electrical connectors include integrated cooling circuits that employ heat exchanger channels for circulating a fluid for convectively cooling bus bars of the connector.

Abstract: An electric machine for an electrified vehicle includes a stator core configured to receive a plurality of windings and an overmolded midsection formed about the stator core. The midsection also defines a first interlocking feature disposed near an end face of the stator core. The electric machine also includes an end cap defining at least a portion of a coolant channel and a second interlocking feature configured to engage the first interlocking feature and create a fluid seal to retain fluid within the coolant channel. The coolant channel is further arranged to encase end portions of the plurality of windings and direct circulating coolant across the end portions.

Abstract: A cooling system for an electric vehicle motor may include a stator having a plurality of coils forming end windings at each of an end of the stator and at least one orifice plate arranged at the end windings of at least one end of the stator, the orifice plate including a plurality of nozzles configured to supply coolant at the end windings.

Abstract: An automotive motor includes a stator and a rotor disposed within the stator. The automotive motor also includes an endplate attached to the rotor that defines a coolant exit hole, an outer edge, and an array of staggered raised flow disruptors disposed radially between the coolant exit hole and outer edge. The array disrupts flow of coolant as the coolant travels from the coolant exit hole along a surface of the endplate toward the outer edge.

Abstract: A power inductor includes a housing and a magnetic core disposed in the housing. The core includes a first segment and a second segment spaced apart from each other to define a gap. The first and second segments are supported in the housing such that the they are movable relative to each other to increase and decrease the size of the gap. A fluid having a positive thermal expansion coefficient is disposed in the housing such that expansion and contraction of the fluid due to change in temperature increases and decreases the gap, respectively.

Abstract: An electric machine configured to propel a vehicle includes a stator, a rotor, and an end plate. The stator has end windings that protrude axially therefrom. The rotor is disposed within the stator. The end plate is secured to an axial end of the rotor. The end plate defines a primary chamber, a secondary chamber that is radially outward of the primary chamber, and a first outlet channel that is configured to direct fluid onto the end windings. The primary chamber is in fluid communication with a fluid source and the secondary chamber. The secondary chamber is in fluid communication with the outlet channel.

Abstract: An electric machine configured to propel a vehicle includes a stator, a rotor, and an end plate. The stator has end windings that protrude axially therefrom. The rotor is disposed within the stator. The end plate is secured to an axial end of the rotor. The end plate defines a primary chamber, a secondary chamber that is radially outward of the primary chamber, and a first outlet channel that is configured to direct fluid onto the end windings. The primary chamber is in fluid communication with a fluid source and the secondary chamber. The secondary chamber is in fluid communication with the outlet channel.

Abstract: A vehicle system is disclosed. The vehicle system includes an automatic transmission fluid cooling conduit. The automatic transmission fluid cooling conduit includes an inlet portion, an outlet portion, and an elbow portion connecting the inlet and outlet portions and having an inner surface defining a cavity in fluid communication with the inlet and outlet portions. The automatic transmission fluid cooling conduit also includes an oleophobic or hydrophobic coating on the inner surface. The oleophobic or hydrophobic coating is configured to reduce eddy currents in the cavity.

Abstract: A power inductor assembly including a power inductor, a vehicle component, and a pair of distribution conduits is provided. The power inductor has a housing supporting a pair of coils. The vehicle component is located above the pair of coils. Each of the pair of distribution conduits is oriented relative to one of the pair of coils below the vehicle component and has one or more openings adjacent the coils to distribute coolant thereto. Each of the one or more openings may define one of a circular shape or a slot shape. Each of the one or more openings may be sized such that exiting coolant substantially uniformly covers the adjacent coil.

Abstract: An electric machine is disclosed. The electric machine includes a stator core defining a cavity and having end-windings protruding from the cavity, and a rotor configured to rotate within the cavity and having end plates defining a plurality of holes for providing coolant. The electric machine also includes one or more layers of an oleophobic or hydrophobic coating disposed on portions of the end plate corresponding to the holes to increase coolant flow to the end-windings.

Abstract: Electronic devices are disclosed including hydrophobic or oleophobic coatings that control coolant flow therein or thereon. In at least one embodiment, a power inverter cold plate is provided including coolant inlet, a coolant outlet, a coolant flow spreading region, a coolant flow collection region, and a coolant heat-transfer region disposed therebetween; and one or more layers of a hydrophobic or oleophobic coating configured to control a flow of coolant in the cold plate. A method may include applying one or more layers of a hydrophobic or oleophobic coating to a power inverter cold plate to control a flow of coolant in the cold plate, the one or more layers being applied to one or more of a coolant flow spreading region, a coolant flow collection region, or a coolant heat-transfer region disposed therebetween. The layers may define coolant flow paths, eliminate recirculation zones, and/or prevent coolant leak paths.

Abstract: An electric machine is disclosed. The electric machine includes a stator core within a transaxle housing and having a channel-less outer surface portion. The electric machine also includes one or more layers of an oleophobic or hydrophobic patterned coating defining boundaries wrapping around a perimeter of the stator core, and one or more layers of an oleophilic or hydrophilic coating on the portion within the boundaries configured to direct coolant flow over the oleophilic or hydrophilic coating within the boundaries.

Abstract: A vehicle powertrain includes a stator defining a circular opening having an inner diameter, and a rotor to rotate within the circular opening such that a gap is formed between a rotor surface and the stator at the inner diameter. The powertrain further includes a repellant, coated on the stator and the rotor surface, to control fluid flow in the gap.

Abstract: An automotive motor includes a stator and a rotor disposed within the stator. The automotive motor also includes an endplate attached to the rotor that defines a coolant exit hole, an outer edge, and an array of staggered raised flow disruptors disposed radially between the coolant exit hole and outer edge. The array disrupts flow of coolant as the coolant travels from the coolant exit hole along a surface of the endplate toward the outer edge.

Abstract: Electronic devices are disclosed including hydrophobic or oleophobic coatings that control coolant flow therein or thereon. In at least one embodiment, an electric machine is provided including a stator core defining a cavity, windings disposed within the cavity and including end windings protruding from the cavity, and one or more layers of an oleophobic coating overlying the end windings and configured to control a flow of coolant over the end windings. A method may include applying one or more layers of a oleophobic coating to end windings of an electric machine stator such that the one or more layers control a flow of coolant over the end windings. The one or more layers may define coolant flow paths, which may direct coolant to areas of the electric machine requiring additional cooling, such as hot spots or neutral points.