Abstract: A vehicle includes an inverter, a climate control system, and a coolant system. The climate control system includes a housing, and a heater core and an electric heater disposed within the housing. The coolant system includes conduit arranged to circulate coolant through the inverter and the heater core. The inverter is disposed upstream of the heater core.

Abstract: A vehicle powertrain has a traction battery, an electric machine, a power converter including a pair of series connected switches defining a phase leg for the electric machine, and a controller. The controller drives the switches with respective pulse width modulated signals to transfer power from the traction battery to the electric machine. Each of the respective pulse width modulated signals defines a low state and a high state. The controller further, responsive to a current flowing through one of the switches exceeding a predetermined threshold and the pulse width modulated signal for the other of the switches having the high state, stops driving the switches.

Abstract: A vehicle on-board charging assembly includes at least one power electronics module and a coolant channel in thermal contact with the at least one power electronics module. The charging assembly also includes a first reactive portion along a wall of the coolant channel defining a first reactive property and a second reactive portion along the wall of the coolant channel defining a second reactive property. The charging assembly further includes a plurality of emitters arranged to activate the first and second reactive portions. The charging assembly also further includes a controller programmed to sequentially activate the emitters to cause peristaltic pumping of coolant through the coolant channel.

Abstract: A vehicle includes a passenger cabin, an inverter, and a coolant system having conduit arranged to circulate coolant through the inverter and an evaporator. A refrigerant system includes a condenser and conduit arranged to circulate refrigerant through the condenser and through the evaporator to absorb heat generated by the inverter. A climate control system is arranged to circulate an airstream through the condenser and into the cabin to heat the cabin.

Abstract: Inductor cooling systems and methods are disclosed. A vehicle inductor cooling system may include an inductor assembly, a flange extending around a periphery of the inductor assembly, and a sealing wall having an outer periphery and a sealing surface forming a seal with the flange. A bottom surface may extend from the outer periphery and a cavity may be defined by the outer periphery, the bottom surface, and the inductor assembly. A coolant inlet may be configured to provide coolant to the cavity. The inductor assembly may include at least one conductive coil wrapped around a core. A bottom portion, optionally only the bottom portion, of the coil may be disposed within the cavity and configured to be directly contacted and cooled by the coolant (e.g., ATF).

Abstract: A vehicle includes a passenger cabin, an inverter, and a coolant system having conduit arranged to circulate coolant through the inverter and an evaporator. A refrigerant system includes a condenser and conduit arranged to circulate refrigerant through the condenser and through the evaporator to absorb heat generated by the inverter. A climate control system is arranged to circulate an airstream through the condenser and into the cabin to heat the cabin.

Abstract: A power inverter includes an array of stacked cards each having switches arranged to transform direct current from a battery into alternating current (AC). Each of the cards also includes a first terminal attached to some of the switches and configured to pass AC therefrom to a first electric machine, and a second terminal attached to other of the switches and configured to pass AC therefrom to a second electric machine. First and second substrates of the power inverter sandwich the switches and terminals.

Abstract: A vehicle includes an oil-cooling system arranged to circulate oil through an electric machine and an oil-to-coolant heat exchanger. A coolant system has conduit arranged to circulate coolant through an inverter, a heater core, and the heat exchanger. A climate control system is arranged to circulate an airstream through the heater core to heat a passenger cabin with waste heat from the electric machine and the inverter.

Abstract: A vehicle includes a passenger cabin, an inverter, and a coolant system having conduit arranged to circulate coolant through the inverter and an evaporator. A refrigerant system includes a condenser and conduit arranged to circulate refrigerant through the condenser and through the evaporator to absorb heat generated by the inverter. A climate control system is arranged to circulate an airstream through the condenser and into the cabin to heat the cabin.

Abstract: This disclosure relates to a coolant cap mix-up prevention system for a motor vehicle. In one example, a motor vehicle includes a first coolant bottle configured for use with a first cap and a second coolant bottle configured for use with a second cap. The second coolant bottle is configured prevent attachment of the first cap to the second coolant bottle. A method is also disclosed.

Abstract: A vehicle includes an inverter, a climate control system, and a coolant system. The climate control system includes a housing, and a heater core and an electric heater disposed within the housing. The coolant system includes conduit arranged to circulate coolant through the inverter and the heater core. The inverter is disposed upstream of the heater core.

Abstract: A power-module assembly includes plates defining pockets and arranged in a stack such that the pockets cooperate to define coolant chambers interleaved with the plates. The assembly further includes cards having a power module encased in a frame. The frame has an outward projecting spacer, and each card is disposed in a corresponding one of the chambers with the spacer contacting a wall of the corresponding chamber to form a coolant passage between the wall and the card.

Abstract: Inductor cooling systems and methods are disclosed. A vehicle may include a transmission case including a coolant inlet and an inductor assembly having a flange extending around a periphery thereof. A thermally conductive cover having a sealing surface may form a seal with the flange. A cavity may be defined between the cover and the inductor assembly and configured to receive coolant from the coolant inlet. A thermal interface material (TIM) may be in contact with a surface of the cover and a surface of the transmission case. The TIM may be a solid or a paste-like substance. If the TIM is solid, it may be in a state of compression between a bottom surface of the cover and the surface of the transmission case. The TIM may transfer heat from coolant in the cavity to the transmission case while the coolant is not being circulated.

Abstract: A vehicle inductor assembly includes an inductor, a thermal plate, an emitter, and a controller. The inductor is secured within a housing. The thermal plate supports the inductor and includes a channel having a flexible wall with actionable particles. The emitter is located adjacent the channel. The controller is programmed to activate the emitter to impart a force upon the particles to move the wall such that a cross-sectional area of the channel is adjusted to influence a flow rate of coolant flowing therethrough. The wall may be a membrane partially secured to an interior of the channel and include the actionable particles. The actionable particles may be one of dielectric and magnetic particles and the emitter may selectively output one of a voltage, an electric field, or a magnetic field to move the dielectric or magnetic particles such that the membrane moves to adjust the cross-sectional area of the channel to influence a flow rate of coolant flowing therethrough.

Abstract: Inductor cooling systems and methods are disclosed. A vehicle inductor cooling system, may include an inductor assembly, a flange extending around a periphery of the inductor assembly, an inductor cover having a sealing surface forming a seal with the flange, a cavity defined by the inductor cover and the inductor assembly, and a first opening defined in the inductor cover configured to provide coolant to the cavity. The flange may include a first recess defined therein that communicates with the first opening and is configured to receive coolant through the first opening and provide it to the cavity. A portion of the cover including the first opening may be configured to form a seal with a coolant inlet of a vehicle transmission case such that coolant is configured to flow through the coolant inlet, through the first opening, into the first recess, and into the cavity.

Abstract: Inductor cooling systems and methods are disclosed. A vehicle inductor cooling system may include an inductor assembly, a flange extending around a periphery of the inductor assembly, and a sealing wall having an outer periphery and a sealing surface forming a seal with the flange. A bottom surface may extend from the outer periphery and a cavity may be defined by the outer periphery, the bottom surface, and the inductor assembly. A coolant inlet may be configured to provide coolant to the cavity. The inductor assembly may include at least one conductive coil wrapped around a core. A bottom portion, optionally only the bottom portion, of the coil may be disposed within the cavity and configured to be directly contacted and cooled by the coolant (e.g., ATF).

Abstract: Inductor cooling systems and methods are disclosed. A vehicle may include a transmission case including a coolant inlet and an inductor assembly having a flange extending around a periphery thereof. A thermally conductive cover having a sealing surface may form a seal with the flange. A cavity may be defined between the cover and the inductor assembly and configured to receive coolant from the coolant inlet. A thermal interface material (TIM) may be in contact with a surface of the cover and a surface of the transmission case. The TIM may be a solid or a paste-like substance. If the TIM is solid, it may be in a state of compression between a bottom surface of the cover and the surface of the transmission case. The TIM may transfer heat from coolant in the cavity to the transmission case while the coolant is not being circulated.

Abstract: Inductor cooling systems and methods are disclosed. A vehicle inductor cooling system, may include an inductor assembly, a flange extending around a periphery of the inductor assembly, an inductor cover having a sealing surface forming a seal with the flange, a cavity defined by the inductor cover and the inductor assembly, and a first opening defined in the inductor cover configured to provide coolant to the cavity. The flange may include a first recess defined therein that communicates with the first opening and is configured to receive coolant through the first opening and provide it to the cavity. A portion of the cover including the first opening may be configured to form a seal with a coolant inlet of a vehicle transmission case such that coolant is configured to flow through the coolant inlet, through the first opening, into the first recess, and into the cavity.

Abstract: Inductor cooling systems and methods are disclosed. A vehicle inductor cooling system may include an inductor assembly secured to a vehicle transmission case and including a core and a conductive coil wrapped around the core. A thermal interface material (TIM) may be spaced apart from the core and may contact a bottom portion of the conductive coil and a surface of the transmission case. The TIM may be configured to transfer heat from the conductive coil to the transmission case. The TIM may be a compressed solid thermal interface material. The TIM may be in contact with at least 85% of a projected surface area of the bottom portion of the conductive coil. The TIM may passively cool the conductive coil(s) of the inductor assembly by transferring heat from the coils to a vehicle transmission case, which may act as a heat sink.

Abstract: A vehicle inductor assembly includes an inductor, a thermal plate, an emitter, and a controller. The inductor is secured within a housing. The thermal plate supports the inductor and includes a channel having a flexible wall with actionable particles. The emitter is located adjacent the channel. The controller is programmed to activate the emitter to impart a force upon the particles to move the wall such that a cross-sectional area of the channel is adjusted to influence a flow rate of coolant flowing therethrough. The wall may be a membrane partially secured to an interior of the channel and include the actionable particles. The actionable particles may be one of dielectric and magnetic particles and the emitter may selectively output one of a voltage, an electric field, or a magnetic field to move the dielectric or magnetic particles such that the membrane moves to adjust the cross-sectional area of the channel to influence a flow rate of coolant flowing therethrough.