Rivian IP Holdings, LLC

Gm Global Technolgoy Operations, Inc.

Faraday & Future Inc.

Dang Dinh Dang

Logan Noel Balliett

Khiet Le

Erik Christopher Hatch

Rolf Blissenbach

Khwaja M Rahman

Jonathan Bird

Larry Xiong

Venkata Harish Kumar Kunatharaju

Venkata Harish Kunatharaju

Terence G Ward

Gabriel Gallegos-Lopez

Peter Bostwick

Omar Abdul Rahman Laldin

David L Schauer

Michael Milani

Yunqi Zheng

Erik Hatch

Duc Q Phan

John Wattleworth

Brandon Given

David S McNaughton

Fan Wu

Shreyas Kapatral

Iftekhar Hasan

Rotor channels extend axially in a rotor to provide flow of coolant in opposite directions to provide a more uniform thermal gradient. The rotor channels include a first rotor channel coupled to a first feed hole via an annulus and extending axially in a first direction to a first side hole, and a second rotor channel coupled to a second feed hole via an annulus and extending axially in the opposite direction to a second side hole. The rotor includes a first end plate arranged at a first axial position that includes the first side hole, and a second end plate arranged at a second axial position that includes the second side hole. The first and second end plates are identical and are arranged azimuthally at an angle to each other. Fluid flows through the channels, cooling the rotor, and then flows past end windings for stator cooling.

Balanced motor cooling using cross flow

Various disclosed embodiments include oil warming systems, electric motors, and vehicles. In an illustrative embodiment a system includes an oil reservoir, a motor stator, and an oil pump. The oil reservoir is configured to hold oil therein. The motor stator is positioned such that at least a portion thereof is positioned within the oil reservoir where the at least the portion of the motor stator is in thermal communication with the oil while the oil reservoir includes the oil therein. The motor stator is configured to warm the oil while in an oil warming mode. The oil pump is fluidly coupled to the oil reservoir and is configured to draw oil out of the oil reservoir.

Oil warming system and method for an electric motor

Aspects of the subject disclosure relate to an electric motor that includes a stator and a rotor. The stator includes a stator body having a plurality of stator coil slots and a plurality of stator coils disposed respectively within the plurality of stator coil slots, each stator coil slot arranged a radially inner side of the stator body facing the rotor. The stator also includes a substrate mechanically coupled to the stator body and configured to receive a fluid via a manifold and distribute the fluid through a cavity formed between the substrate and the stator body. Each stator coil slot includes an opening forming a channel that extends longitudinally across the stator body for distributing the fluid through the channel and thermally interact with the plurality of stator coils and the stator body. Accordingly, the temperature of the electric motor can be regulated.

Stator core axial channels for temperature regulation of electric motor

Aspects of the subject disclosure relate to an electric motor that includes a stator. The stator includes a stator body having stator coils. The stator also includes a first substrate coupled to a first end of the stator body and configured to receive a fluid via a first manifold. The stator also includes a second substrate coupled to a second end of the stator body and configured to receive the fluid via a second manifold. The first substrate includes entry slots that form respective axial channels with exit slots of the second substrate to distribute the fluid across the stator body in a first direction. The second substrate includes entry slots that form respective axial channels with exit slots of the first substrate to distribute the fluid across the stator body in a second direction different from the first direction. Accordingly, the temperature of the electric motor can be regulated.

Alternate stator slots using common manifold interface for bidirectional stator cooling

A motor stator for a motor is disclosed. The motor stator includes a stator body and a plurality of windings. The stator body includes a weld end, a crown end, and a plurality of slots arranged circumferentially and extending axially therethrough between the weld end and the crown end, the slots including a plurality of layers arranged in a radial direction with layers being organized in conductor pairs. Each winding includes a plurality of coils and a plurality of weld pairs. Each weld pair includes legs of two respective coils joined together to form an electrical connection between the two respective coils. The plurality of weld pairs includes one or more jumper weld pairs arranged to jump the respective winding between two respective conductor pairs.

Motor stator with semi-staggered winding layout utilizing complex twisting

A motor stator for a motor is disclosed. The motor stator includes a stator body and a plurality of windings. The stator body includes a weld end, a crown end, and a plurality of slots arranged circumferentially and extending axially therethrough between the weld end and the crown end. Each winding including a phase lead, a neutral lead, and a plurality of coils. The plurality of coils include a same-layer lead coil including two legs that spans across multiple slots of the plurality of slots and that are inserted into respective slots at a same layer thereof. The same-layer lead coil positions the phase lead at the weld end. The neutral lead and welds joining the plurality of coils are all positioned at the weld end.

Motor stator with semi-staggered winding layout and single-sided phase, neutral, and coil connection welds

Various disclosed embodiments include illustrative sprayer assemblies, electric motor assemblies, and vehicles with cooling assemblies for stator windings of electric motors. An illustrative sprayer assembly includes a first spray device assembly configured to receive a fluid and further configured to spray the fluid therefrom. A second spray device assembly is configured to receive the fluid and is further configured to spray the fluid therefrom. A connecting tube is fluidly couplable to the first spray device assembly and the second spray device assembly and is configured to provide the fluid from the first spray device assembly to the second spray device assembly.

Coolant fluid sprayer assembly for electric motor

A rotor/stator assembly for a motor, including: a rotor shaft including an internal channel; a rotor core disposed adjacent to the rotor shaft; and end windings disposed adjacent to an end of the rotor shaft and an end of the rotor core; wherein the rotor shaft includes a passage passing through a wall of the rotor shaft adjacent to the end thereof, thereby forming a path by which a cooling fluid passes from the internal channel of the rotor shaft to the end of the rotor core and the end windings when the rotor shaft and rotor core are rotated/rotating.

Rotor assembly and method for motor end winding cooling and bearing lubrication

An apparatus comprising a coupling member. The coupling member can be disposed between a first portion of a busbar connectable to a first component of a drive unit assembly and a second portion of the busbar connectable to a second component of the drive unit assembly. The coupling member can couple the first portion of the busbar with the second portion of the busbar. The coupling member can include a first segment, a second segment, and a third segment. The first segment can be parallel to the third segment and the first segment can be perpendicular to the second segment.

Stator busbar

Various disclosed embodiments include illustrative stator winding interface devices, electric motors, and methods of manufacturing an electric motor. In an illustrative embodiment, a stator winding interface device includes phase plates, a neutral plate, and a structure configured to maintain the phase plates and the neutral plate in a rigid orientation.

Apparatuses and methods for rigidly integrating phase and neutral plates

Various disclosed embodiments include oil systems, electric motors, and vehicles. In an illustrative embodiment an electrical motor system includes an oil reservoir, a motor, and an oil delivery system. The oil reservoir is configured to hold oil therein. The oil delivery system includes a heat exchanger. The oil delivery system is configured to operate in a low-temperature mode, bypassing the heat exchanger, while the oil temperature is below a first predetermined temperature; operate in a high-temperature mode, directing oil traversing the oil delivery system through the heat exchanger while the oil temperature is above a second predetermined temperature; and operate in an intermediate-temperature mode, partially bypassing the heat exchanger while the oil temperature is between the first predetermined temperature and the second predetermined temperature.

Temperature controlled heat exchanger bypass for an electric motor

A connection rod seal for sealing an interface between a connection rod and a motor cover of an electric motor is disclosed. The connection rod seal includes a body, a radial seal, and a face seal. The body includes a through hole formed therein. The through hole is adapted to receive the connection rod. The radial seal is positioned within the through hole and is adapted to form a seal with the connection rod. The face seal is positioned at a bottom surface of the body and extends completely around the through hole at the bottom surface. The face seal is adapted to form a seal with an outer surface of the motor cover.

Electric axle connection seal

A winding arrangement for a stator of an electric motor includes winding hairpins arranged to form one or more phases. The stator includes a plurality of motor teeth forming a plurality of slots each configured to accommodate multiple layers. A first set of winding hairpins spanning of M slots are coupled in series and coupled to a phase lead, and are arranged sequentially in a first azimuthal direction. A jumper is arranged in a layer and is coupled in series with the first set of winding hairpins. A second set of winding hairpins configured to span of M slots are coupled in series between the jumper and a neutral lead. The second set of winding hairpins are arranged sequentially in the opposite azimuthal direction, and along with the first set of winding hairpins and the jumper, form a continuous electrical path between the phase lead and the neutral lead.

Balanced winding layouts for electric motors

A rotor assembly for a permanent magnet motor, including: a rotor shaft comprising an internal cavity having an inlet and an outlet; and a rotor core disposed about the rotor shaft, comprising an internal channel having an inlet and an outlet; wherein the outlet of the internal cavity of the rotor shaft is coupled to the inlet of the internal channel of the rotor core; and wherein the internal cavity of the rotor shaft and the internal channel of the rotor core are configured to circulate a cooling fluid through the rotor shaft and the rotor core. The rotor core includes a plurality of permanent magnets adapted to interact with a stator assembly disposed about/adjacent to the rotor core.

Growing community of inventors

Garden Grove, CA, United States of America

Dang Dinh Dang