Abstract: A cooling system for a drivetrain of an electric vehicle includes a coolant circuit directing a flow of coolant through a first inverter and a second inverter of the drivetrain, and an adjustable flow valve positioned along the coolant circuit to selectably alter proportions of the flow of coolant directed through each of the first inverter and the second inverter. A method of operating a cooling system for a first inverter and a second inverter of a vehicle drivetrain includes commanding a speed and torque of each of the first and second inverter, and estimating losses and temperature of each of the first inverter and the second inverter as a result of the commanded speed and torque. A valve position of an adjustable flow valve operably connected to the first inverter and the second inverter is selected, and a change of the valve position is commanded.

Abstract: A power control system for an electric vehicle includes a power inverter comprising a switch module including a plurality of power switches, a controller board, and a gate driver board in communication with the controller board and configured to drive gates of the plurality of switches. A first housing is made of polymer composite, encloses the power inverter, defines a first cooling cavity in thermal communication with a first surface of the switch module, and encapsulates a portion of at least one of the switch module, the controller board and the gate driver board.

Abstract: An electronic solid-state switch assembly includes a base plate and a heat exchanger; an electrically insulating layer and a direct bonded substrate affixed to the base plate; a first terminal and a second terminal; a plurality of power transistors; a plurality of gate drivers; a communication interface, a current sensor, and a snubber circuit; and a controller. The plurality of gate drivers are operatively coupled to the plurality of power transistors. The plurality of power transistors are arranged in parallel on the direct bonded substrate between the first terminal and the second terminal. The plurality of power transistors are electrically connected to the first terminal and to the second terminal. The controller is in communication with the plurality of gate drivers, the current sensor, and the communication interface. The controller is configured to control, via the plurality of gate drivers, the plurality of power transistors.

Abstract: An inverter assembly for a motor vehicle includes a housing with an inlet end for receiving a flow of coolant and an outlet end for discharging the flow of coolant. The assembly further includes a first plurality of power transistors conducting and switching an electrical current and generating a first amount of heat. The assembly further includes a second plurality of power transistors conducting and switching the electrical current and generating a second amount of heat that is less than the first amount of heat. A heat sink includes a plate with a first section adjacent to the first plurality of power transistors and a second section adjacent to the second plurality of power transistors. The heat sink further includes a first plurality of fins for drawing the first amount of heat from the first section and a guide vane directing the flow of coolant toward the first plurality of fins.

Abstract: An electronic solid-state switch assembly includes a base plate and a heat exchanger; an electrically insulating layer and a direct bonded substrate affixed to the base plate; a first terminal and a second terminal; a plurality of power transistors; a plurality of gate drivers; a communication interface, a current sensor, and a snubber circuit; and a controller. The plurality of gate drivers are operatively coupled to the plurality of power transistors. The plurality of power transistors are arranged in parallel on the direct bonded substrate between the first terminal and the second terminal. The plurality of power transistors are electrically connected to the first terminal and to the second terminal. The controller is in communication with the plurality of gate drivers, the current sensor, and the communication interface. The controller is configured to control, via the plurality of gate drivers, the plurality of power transistors.

Abstract: A rotor for an electric machine includes a heat pipe cooling system. A rotor core has a number of cavities internal to the rotor core. The cavities are surrounded by a wall defined by the rotor core. A magnetic element disposed in the at least one cavity leaving a void in the at least one cavity between the magnetic element and the wall. A heat pipe evaporator is disposed in the void and conforms to the available space, contacting the magnetic element and the wall to remove heat from the rotor core.

Abstract: An inverter assembly for a motor vehicle includes a housing with an inlet end for receiving a flow of coolant and an outlet end for discharging the flow of coolant. The assembly further includes a first plurality of power transistors conducting and switching an electrical current and generating a first amount of heat. The assembly further includes a second plurality of power transistors conducting and switching the electrical current and generating a second amount of heat that is less than the first amount of heat. A heat sink includes a plate with a first section adjacent to the first plurality of power transistors and a second section adjacent to the second plurality of power transistors. The heat sink further includes a first plurality of fins for drawing the first amount of heat from the first section and a guide vane directing the flow of coolant toward the first plurality of fins.

Abstract: A vascular jet cooling system for use with a planar power module and a coolant supply includes a manifold housing and one or more jet impingement plates. The manifold housing is constructed of a dielectric polymer molding material, and defines a coolant inlet port configured to fluidly connect to the coolant supply, an internal cavity in fluid communication with the coolant inlet port and containing the power module, and a coolant outlet port in fluid communication with the internal cavity. The jet impingement plate(s) is arranged in the internal cavity. Openings of the plates direct coolant passing through the coolant inlet port onto a respective major surface of the power module. A power module assembly includes a planar power module and the vascular jet cooling system. A method of constructing the power module assembly uses sacrificial materials and overmolding of the jet impingement plates.

Abstract: A fuel injector for an internal combustion engine. The fuel injector has a needle and a nozzle that inter-relate with each other in assembly. Relative movement between the needle and nozzle bring the fuel injector between a closed state of operation and an open state of operation amid use of the fuel injector. The nozzle has one or more passages therein through which fuel is discharged.

Abstract: A fuel injector for an internal combustion engine. The fuel injector has a needle and a nozzle that inter-relate with each other in assembly. Relative movement between the needle and nozzle bring the fuel injector between a closed state of operation and an open state of operation amid use of the fuel injector. The nozzle has one or more passages therein through which fuel is discharged. Fuel flow is precluded at a sac volume of the fuel injector.

Abstract: An internal combustion engine includes a combustion chamber formed by cooperation of a cylinder bore formed in a cylinder block, a cylinder head and a piston. A combustion ignition device is disposed in the combustion chamber and includes a nozzle defining a pre-chamber, a barrier discharge plasma igniter, including a tip portion disposed in the pre-chamber and a plurality of apertures disposed in the nozzle. The pre-chamber is in fluidic communication with the combustion chamber via the plurality of apertures. A controller is in communication with the engine and the barrier discharge plasma igniter.

Abstract: A bi-fuel vehicle has an Internal Combustion Engine (ICE) to provide motive power to the vehicle by combustion of a liquid fuel and gas-phase fuel. The vehicle has a dual fuel tank including a liquid fuel tank to receive liquid fuel, contain the liquid fuel, and supply the liquid fuel for combustion in the ICE. The vehicle has a pressurizable gas-phase fuel tank defined by a wall. A gas-phase fuel is permeable through the wall. The pressurizable gas-phase fuel tank is to receive the gas-phase fuel, contain the gas-phase fuel, and supply the gas-phase fuel for combustion in the ICE. A shell envelops the pressurizable gas-phase fuel tank and defines an interior space of the liquid fuel tank. The wall is in fluid communication with the interior space. The interior space is to receive the permeated gas-phase fuel.

Abstract: An internal combustion engine includes a combustion chamber formed by cooperation of a cylinder bore formed in a cylinder block, a cylinder head and a piston. A combustion ignition device is disposed in the combustion chamber and includes a nozzle defining a pre-chamber, a barrier discharge plasma igniter, including a tip portion disposed in the pre-chamber and a plurality of apertures disposed in the nozzle. The pre-chamber is in fluidic communication with the combustion chamber via the plurality of apertures. A controller is in communication with the engine and the barrier discharge plasma igniter.

Abstract: A bi-fuel vehicle has an Internal Combustion Engine (ICE) to provide motive power to the vehicle by combustion of a liquid fuel and gas-phase fuel. The vehicle has a dual fuel tank including a liquid fuel tank to receive liquid fuel, contain the liquid fuel, and supply the liquid fuel for combustion in the ICE. The vehicle has a pressurizable gas-phase fuel tank defined by a wall. A gas-phase fuel is permeable through the wall. The pressurizable gas-phase fuel tank is to receive the gas-phase fuel, contain the gas-phase fuel, and supply the gas-phase fuel for combustion in the ICE. A shell envelops the pressurizable gas-phase fuel tank and defines an interior space of the liquid fuel tank. The wall is in fluid communication with the interior space. The interior space is to receive the permeated gas-phase fuel.

Abstract: A method for controlling a vehicle employing a powertrain system and a braking system coupled to vehicle wheels includes interrupting vehicle creep operation upon detect absence of a qualified operator in a driver's seat when the vehicle is in a propulsion state.

Abstract: An internal combustion engine includes a cylinder block defining a combustion chamber therein, and a cylinder head mated to the cylinder block such that the cylinder head covers the combustion chamber. The internal combustion engine also includes a fuel nozzle configured for injecting a fuel into the combustion chamber and a plasma igniter configured for ejecting a plasma into the combustion chamber to ignite the fuel. The plasma igniter extends through the cylinder head and protrudes into the combustion chamber. The internal combustion engine further includes a dielectric coating disposed on the cylinder head. A vehicle including the internal combustion engine is also disclosed.

Abstract: A method for controlling a vehicle employing a powertrain system and a braking system coupled to vehicle wheels includes interrupting vehicle creep operation upon detect absence of a qualified operator in a driver's seat when the vehicle is in a propulsion state.

Abstract: A piston for an internal combustion engine is located within a cylinder of the engine. The piston includes a dish-shaped depression in a surface of the piston exposed to a combustion chamber of the cylinder providing a recess from a nominal top of the piston. The depression includes a depression boundary located at the nominal top of the piston and proximate to an outer diameter of the piston, an apex, and inclined walls connecting the apex to the depression boundary.

Abstract: A direct injection engine includes a fuel injector receiving a flow of pressurized fuel. The fuel injector provides fuel injections directly into a combustion chamber of the engine. The fuel injector includes a first fuel injector nozzle opening directing with a first narrow injection angle a first portion of a fuel injection mass at a spark gap of a spark plug. The fuel injector further includes a second fuel injector nozzle opening dispersing with a second wider injection angle a second portion of the fuel injection mass within the combustion chamber.

Abstract: A direct injection engine includes a fuel injector receiving a flow of pressurized fuel. The fuel injector provides fuel injections directly into a combustion chamber of the engine. The fuel injector includes a first fuel injector nozzle opening directing with a first narrow injection angle a first portion of a fuel injection mass at a spark gap of a spark plug. The fuel injector further includes a second fuel injector nozzle opening dispersing with a second wider injection angle a second portion of the fuel injection mass within the combustion chamber.