Delphi Technologies, Inc.

Remy Technologies, LLC

Colin J Hamer

Albert Anthony Skinner

Bradley Duane Chamberlin

Mark Albert Paul

Harry Oliver Levers, Jr

Cary Ramey

Koon Hoong Wan

Kenneth P Senseman

Edgard Wolf

Raymond O Butler, Jr

Alex Spencer Creviston

Andrew Meyer

Harry O Levers

Andrew Dragon

Brad Chamberlin

Arlen Phillip Suter

John D Truong

Klaus Gernert

David D Jackson

Ronald Erli

Hector J Herrera

André V Scaff

Thomas Goesch

Mark L Whittemore

John Matthew Sigler

James R Davis

Max A Butcher

Oscar Gamboa

Matthew Obras

Gary Lee Adams

An ignition coil for delivering a spark-generating current to a spark plug includes a magnetically-permeable core; a primary winding disposed outward of the core; and a secondary winding radially surrounding the primary winding and inductively coupled to the primary winding, the secondary winding having a low-voltage end and a high-voltage end. The secondary winding includes a secondary winding first section proximal to the low-voltage end and having a first thickness. The secondary winding also includes a secondary winding second section proximal to the high-voltage end and having a second thickness that is less than the first thickness of the secondary winding first section.

Ignition coil

Some embodiments of the invention provide an electric machine module including a housing that defines a machine cavity. A coolant jacket can be at least partially defined by the housing. In some embodiments, a plurality of coolant apertures can be disposed through portions of the housing to fluidly connect the coolant jacket and the machine cavity. One or more solenoid assemblies can be at least partially supported by the housing and positioned substantially adjacent to at least some of the coolant apertures. The solenoid assemblies can be configured to regulate passage of a coolant into the machine cavity from the coolant jacket.

Electric machine module cooling system and method

A rotor assembly for a permanent magnet electric machine includes a plurality of rotor laminations joined to form a rotor body. Each of the plurality of rotor laminations includes a plurality of slots. One or more permanent magnets are mounted within respective ones of the plurality of slots. Each of the one or more permanent magnets includes a thermal enhancement bonding coating. A method of forming a rotor assembly is also disclosed.

Permanent magnet electric machine having magnets provided with a thermal enhancement bonding coating

An electric machine housing includes a housing body having an outer surface provided with a plurality of materially integrally formed ribs defining a plurality of coolant channels. Each of the plurality of materially integrally formed ribs has an outer surface portion. A sleeve is provided on the housing body extending about the outer surface. The sleeve has an inner surface section that is matingly engaged with the outer surface portion of each of the materially integrally formed ribs.

Electric machine including a housing having materially integrally formed coolant channels and an outer sleeve

An electric power source supplies electrical power to an electric machine of a vehicle via a plurality of high voltage lines. A plurality of connections are disposed within a housing for connecting the high voltage lines. A cover member encloses a hidden magnet and is removably secured to the housing so that removal is necessary to obtain access to the high voltage lines. A reed switch is mounted proximate the cover member, when secured, within a magnetic field of the magnet, whereby the reed switch is closed when the cover member is secured and is open when the cover member is removed. A controller is controllably coupled to the power source via a control connector and circuit of the electric machine. Such circuit extends from the reed switch to the controller, where the controller causes the electric power source to stop supplying electrical power when the cover member is removed.

Safety cover with integrated magnet for reed switch

An interlock system and method are provided for protecting high voltage electrical couplings. The interlock system may control access to the electrical couplings based on the voltage of the electrical couplings. The interlock system may also selectively energize and de-energize the electrical couplings based on the position of a lid.

High voltage protection interlock system for serviceability

An electro-dynamic machine is provided and includes stator assembly end turns and a coolant chargeable bladder disposable to contact the end turns.

Electro-dynamic machine with coolant chargeable bladder

An electric machine includes a housing, a stator fixedly mounted relative to the housing, and a rotor assembly rotatably mounted relative to the stator. The rotor assembly includes a plurality of rotor laminations forming a rotor body, one or more permanent magnets provided in the rotor body, and a sleeve extending around the one or more permanent magnets. The sleeve provides a thermal interface between the one or more permanent magnets and the rotor body.

Permanent magnet electric machine including permanent magnets having a sleeve formed from a thermal interface material

A stator assembly for an electric machine including a stator core supporting a plurality of electrical conductors. A plurality of elongated insulator spacers is interwoven between the conductors proximate connection ends thereof in axially spaced relation to the stator core.

Electric machine with insulator spacer

A stator includes a stator core having a plurality of slot segments, a plurality of stator winding conductors arranged in select ones of the plurality of slot segments, a jumper conductor interconnecting select ones of the plurality of stator winding conductors to form one or more stator windings, a common conductor connected to at least one of the stator winding conductors, a phase conductor connected to corresponding ones of the one or more stator windings, and a composite sleeve provided on at least one of the jumper conductor, the common conductor, and the phase conductor. The composite sleeve includes a first sleeve, and a second sleeve positioned about the first sleeve. One of the first and second sleeves is formed from a compressed amide synthetic fiber. The first and second sleeves cooperate to provide protection for the conductor from external elements.

Stator including conductors provided with a composite sleeve

A machine includes a high voltage element and an enclosure surrounding the high voltage element. The enclosure includes a first insulating insert disposed at least partially within a first wall and being electrically non-conductive and surrounding a first conductive insert and an enclosure cover formed at least partially of an electrically non-conducting substrate and having a first opening formed therein sized to allow a first fastener or an extension of the first conductive insert to pass through it. Removal of the enclosure cover causes the high high-voltage element to cease operating.

Machine with high voltage enclosure cover

A method of blocking electro-magnetic interference (EMI) in an electric machine having a housing including an interior portion, an opening leading to the interior portion, and an enclosure positioned about the opening, includes positioning an EMI blocking member in the enclosure across the opening. The EMI blocking member includes an insulating layer having a first surface and a second surface. An EMI shield member is positioned on one of the first and second surfaces. The EMI shield member includes a surface formed from an electrically conductive material that substantially covers the one of the first and second surfaces. The EMI shield member is grounded to the housing. The EMI shield member is configured and disposed to block EMI release from the housing via the enclosure.

Method of blocking electro-magnetic interference (EMI) in an electric machine and apparatus

Some embodiments of the invention provide an electric machine module comprising an electric machine including a rotor assembly and a rotor hub. In some embodiments, the module can include a output shaft substantially circumscribed by the rotor hub and including at least one channel and at least one coolant outlet. A cavity can be formed by at least the output shaft and the rotor hub. Some embodiments can include a sleeve substantially circumscribing a portion of the output shaft with at least a portion of the sleeve positioned substantially within the cavity between the output shaft and the rotor hub. The sleeve can include at least one groove.

Electric machine cooling system and method

An ignition apparatus includes a core, primary and secondary windings and a loop-shaped magnetic return path structure. The structure includes layers of wound strip steel or wound ferritic wire stacked in an outward fashion. The core is placed in an interior of the loop forming at least one air gap between a core end surfaces and the structure. A combined core and magnetic return path structure includes a continuous loop formed by winding ferritic wire either on a spool or on a mandrel and is then bonded. The bonded winding is cut to form two C-shaped portions. Each C-shaped portion has a central yoke that extends into a pair of parallel legs. The C-shaped portions are re-assembled over primary and second windings so that the legs form a pair of parallel branches. One branch acts as the core and the other branch acts as the magnetic return path.

An ignition apparatus includes a cylindrical core made from magnetically-permeable material and a C-shaped magnetic return path structure that is made from a stack of silicon steel laminations. A tightly controlled air gap is provided between one leg of the C-shaped structure and an end face of the core, forming a magnetic circuit having a high magnetic permeability, which overall reduces the number of primary winding turns needed, thereby reducing the amount of copper wire. In addition, the circular cross-section of the core reduces the mean length per turn (MLT) of the primary winding because the primary winding can be wound directly on the core, which in turn also reduces the MLT of the secondary winding. The reduced MLT also reduces the amount of copper wire. The structure may be replaced using a magnetically-permeable, U-shaped shield.

Growing community of inventors

El Paso, TX, United States of America

Colin J Hamer