Abstract: In accordance with exemplary embodiments, a drive system is provided for an electric or hybrid electric vehicle that provides reduces electromagnetic emissions. The system includes, but is not limited to, an electric motor and a transmission having a collar for receiving a portion of a drive shaft. The collar has an inside diameter proportioned to an outside diameter of the drive shaft to cause capacitive coupling between the transmission and the drive shaft thereby reducing electromagnetic emissions along the drive shaft.

Abstract: An integration assembly for a battery pack mounted between the passenger cabin floor panel of an electric vehicle and the driving surface is provided, the assembly utilizing a multi-layer thermal barrier interposed between the battery pack enclosure and the passenger cabin floor panel, where the multi-layer thermal barrier provides noise isolation, thermal isolation and vibration damping, and where the multi-layer thermal barrier is compressed when the battery pack enclosure is mounted to the vehicle. The multi-layer thermal barrier is comprised of a first layer formed from a compressible and conformable elastic material and a second layer formed from a conformable thermally insulating material. The multi-layer thermal barrier may also include a moisture barrier layer that encases the first and second layers, for example a moisture barrier layer fabricated from a plastic. A sealant may be used to seal and bond the moisture barrier layer to the battery pack enclosure.

Abstract: A thermal management system is provided that minimizes the effects of thermal runaway within a battery pack, the system using an integrated battery venting assembly comprised of an integrated exhaust port, a valve retention plate that covers the exhaust port and includes a plurality of retention plate ports, and a plurality of valves that are configured to seal the retention plate ports under normal conditions and unseal the retention plate ports during thermal runaway. As hot gas passes through the retention plate ports, the plate is configured to melt and be ejected, thereby allowing subsequent hot gas to pass through the larger exhaust port. A perforated cover plate may be used to protect the external surfaces of the retention plate and valves. An internally mounted exhaust guide may be used to direct the flow of hot gas expelled during the thermal runaway event.

Abstract: A thermal management system is provided that minimizes the effects of thermal runaway within a battery pack. The system is comprised of a sealed battery pack enclosure configured to hold a plurality of batteries, where the battery pack enclosure is divided into a plurality of sealed battery pack compartments. The system also includes a plurality of battery venting assemblies, where at least one battery venting assembly is integrated into each of the sealed battery pack compartments, and where each of the battery venting assemblies includes an exhaust port integrated into an outer wall of the battery pack compartment and a valve, the valve being configured to seal the exhaust port under normal operating conditions and to unseal the exhaust port when at least one of the batteries within the battery pack compartment enters into thermal runaway.

Abstract: A manifold is provided for supporting a power module assembly with a plurality of power modules. The manifold includes a first manifold section. The first face of the first manifold section is configured to receive the first power module, and the second face of the first manifold section defines a first cavity with a first baseplate thermally coupled to the first power module. The first face of the second manifold section is configured to receive the second power module, and the second face of the second manifold section defines a second cavity with a second baseplate thermally coupled to the second power module. The second face of the first manifold section and the second face of the second manifold section are coupled together such that the first cavity and the second cavity form a coolant channel. The first cavity is at least partially staggered with respect to second cavity.

Abstract: A filter for an automotive electrical system includes a substrate having first and second conductive members. First and second input terminals are mounted to the substrate. The first input terminal is electrically connected to the first conductive member, and the second input terminal is electrically connected to the second conductive member. A plurality of capacitors are mounted to the substrate. Each of the capacitors is electrically connected to at least one of the first and second conductive members. First and second power connectors are mounted to the substrate. The first power connector is electrically connected to the first conductive member, and the second power connector is electrically connected to the second conductive member. A common mode choke is coupled to the substrate and arranged such that the common mode choke extends around at least a portion of the substrate and the first and second conductive members.

Abstract: In accordance with exemplary embodiments, a drive system is provided for an electric or hybrid electric vehicle that provides reduces electromagnetic emissions. The system includes, but is not limited to, an electric motor and a transmission having a collar for receiving a portion of a drive shaft. The collar has an inside diameter proportioned to an outside diameter of the drive shaft to cause capacitive coupling between the transmission and the drive shaft thereby reducing electromagnetic emissions along the drive shaft.

Abstract: A power electronics assembly is provided. A first support member includes a first plurality of conductors. A first plurality of power switching devices are coupled to the first support member. A first capacitor is coupled to the first support member. A second support member includes a second plurality of conductors. A second plurality of power switching devices are coupled to the second support member. A second capacitor is coupled to the second support member. The first and second pluralities of conductors, the first and second pluralities of power switching devices, and the first and second capacitors are electrically connected such that the first plurality of power switching devices is connected in parallel with the first capacitor and the second capacitor and the second plurality of power switching devices is connected in parallel with the second capacitor and the first capacitor.

Abstract: A thermal management system is provided that minimizes the effects of thermal runaway within a battery pack, the system using an integrated battery venting assembly comprised of an integrated exhaust port, a valve retention plate that covers the exhaust port and includes a plurality of retention plate ports, and a plurality of valves that are configured to seal the retention plate ports under normal conditions and unseal the retention plate ports during thermal runaway. As hot gas passes through the retention plate ports, the plate is configured to melt and be ejected, thereby allowing subsequent hot gas to pass through the larger exhaust port. A perforated cover plate may be used to protect the external surfaces of the retention plate and valves. An internally mounted exhaust guide may be used to direct the flow of hot gas expelled during the thermal runaway event.

Abstract: A thermal management system is provided that minimizes the effects of thermal runaway within a battery pack. The system is comprised of a sealed battery pack enclosure configured to hold a plurality of batteries, where the battery pack enclosure is divided into a plurality of sealed battery pack compartments. The system also includes a plurality of battery venting assemblies, where at least one battery venting assembly is integrated into each of the sealed battery pack compartments, and where each of the battery venting assemblies includes an exhaust port integrated into an outer wall of the battery pack compartment and a valve, the valve being configured to seal the exhaust port under normal operating conditions and to unseal the exhaust port when at least one of the batteries within the battery pack compartment enters into thermal runaway.

Abstract: A printed circuit board includes, but is not limited to, a plurality of electrically conductive layers and a plurality of dielectric layers. Each dielectric layer is interposed between adjacent conductive layers to form a body of alternate conductive layers and dielectric layers. At least one of the electrically conductive layers protrudes beyond an end of the body.

Abstract: A power electronics assembly is provided. A first support member includes a first plurality of conductors. A first plurality of power switching devices are coupled to the first support member. A first capacitor is coupled to the first support member. A second support member includes a second plurality of conductors. A second plurality of power switching devices are coupled to the second support member. A second capacitor is coupled to the second support member. The first and second pluralities of conductors, the first and second pluralities of power switching devices, and the first and second capacitors are electrically connected such that the first plurality of power switching devices is connected in parallel with the first capacitor and the second capacitor and the second plurality of power switching devices is connected in parallel with the second capacitor and the first capacitor.

Abstract: A manifold is provided for supporting a power module assembly with a plurality of power modules. The manifold includes a first manifold section. The first face of the first manifold section is configured to receive the first power module, and the second face of the first manifold section defines a first cavity with a first baseplate thermally coupled to the first power module. The first face of the second manifold section is configured to receive the second power module, and the second face of the second manifold section defines a second cavity with a second baseplate thermally coupled to the second power module. The second face of the first manifold section and the second face of the second manifold section are coupled together such that the first cavity and the second cavity form a coolant channel. The first cavity is at least partially staggered with respect to second cavity.

Abstract: A filter for an automotive electrical system includes a substrate having first and second conductive members. First and second input terminals are mounted to the substrate. The first input terminal is electrically connected to the first conductive member, and the second input terminal is electrically connected to the second conductive member. A plurality of capacitors are mounted to the substrate. Each of the capacitors is electrically connected to at least one of the first and second conductive members. First and second power connectors are mounted to the substrate. The first power connector is electrically connected to the first conductive member, and the second power connector is electrically connected to the second conductive member. A common mode choke is coupled to the substrate and arranged such that the common mode choke extends around at least a portion of the substrate and the first and second conductive members.