Atieva, Inc.

Emad Dlala

Jeremy Franz Mayer

Richard J Biskup

Balaji M Maniam

Barnaby James Gerard Lewis

Aberto Bassanese

David Moseley

Mohammad Mahmoudi

Vivek Meenakshi Sundaram

Yateendra Deshpande

Balazs Palfai

Shun-Cheng Hung

Mingkai Mu

Michael Tebbe

Jiajun Wu

Roberto Melendez

Azat Suleimenov

Michael Abosch

Mohammed Mahmoudi

Anandakumar Subbiah

Sahil Rahimi

A fluid flow system for a rotatable shaft assembly includes a first fluid flow device installed in a rotatable shaft, and a second fluid flow device installed in the rotatable shaft, spaced axially apart from the first fluid flow device. The first fluid flow device includes a wall portion having a radial dimension that retains oil in the rotatable shaft. The second fluid flow device includes a wall portion having a radial dimension that facilitates discharge of oil from the radial shaft. The first and second fluid flow devices each include a plurality of baffles on the respective wall portions thereof. The plurality of baffles drive the flow of fluid in an axial direction, from the first fluid flow device toward the second fluid flow device, as the first and second fluid flow devices rotate together with the rotatable shaft.

Lubrication and cooling system for rotatable components

An electric motor comprises: a rotor; a stator comprising a stack of laminations, wherein windings of the stator comprise wires that have individual insulation, the wires forming slot windings positioned in slots of the stator, the wires further forming end windings positioned outside the slots at each end of the stator; varnish in the slots of the stator, the varnish contacting the laminations and the slot windings, and wherein the varnish does not contact the end windings of at least one of the ends of the stator; and a cooling system to apply liquid coolant to at least the end windings, wherein the liquid coolant passes between the wires of the end windings.

Electric motor with unvarnished end winding for stator

An electric motor comprises: a stator having slots; and a rotor including a stack of rotor laminations, the rotor comprising: a first substack of the rotor laminations, wherein the rotor laminations in the first substack include first rivet holes and first magnet holes with first permanent magnets; and a second substack of the rotor laminations, wherein the rotor laminations in the second substack include second rivet holes and second magnet holes with second permanent magnets, and wherein an orientation of the first sub stack and the second substack relative to each other provides the rotor with a skew.

Skewed rotor for electric motor

A hybrid rotor assembly is provided. The assembly utilizes two different types of magnets within the lamination cavities of the lamination stack: sintered permanent magnets and bonded magnets.

Electric motor with permanent magnets abutted by tabs in lamination cavities

An electric motor comprises: a rotor having poles equaling a first number; and a stator having slots equaling a second number, the stator having stator windings formed by conductors wound in a wave pattern around the stator, wherein a third number of the conductors are located in each of the slots, wherein the conductors form three balanced parallel paths through the slots, each of the conductors in the three balanced parallel paths undergoing a same number of pitch turns, each of the pitch turns being either a standard pitch turn or a nonstandard pitch turn, the standard pitch turn involving wrapping around slots equaling the second number divided by the first number, the nonstandard pitch turn involving wrapping around more or fewer slots than the standard pitch turn, wherein each of the three balanced parallel paths forms a repeating pattern throughout the slots.

Patterns for balanced stator windings in electric motor

An electric motor cooling system is provided that utilizes stator-integrated axial coolant channels and a coolant manifold centrally located within the stator to efficiently remove motor assembly heat. In order to increase the velocity of the coolant exiting the axial coolant channels, thereby improving end winding cooling uniformity, end laminations are integrated into the stator which restrict the flow of coolant from the axial coolant channels.

Motor cooling system utilizing axial coolant channels

An electric motor cooling system is provided that utilizes stator-integrated axial coolant channels and a coolant manifold centrally located within the stator to efficiently remove motor assembly heat. In order to improve end winding cooling uniformity, two or more end laminations are included on either end of the stator assembly which restrict and direct the flow of coolant exiting the axial coolant channels.

An electric motor cooling system is provided that utilizes stator-integrated axial coolant channels and a coolant manifold centrally located within the stator to efficiently remove motor assembly heat. The coolant manifold includes a middle member that allows coolant to enter the axial coolant channels via transition laminations, where the transition laminations include coolant distribution channels that direct the flow of coolant entering into the manifold into the stator-integrated axial coolant channels.

Stator-integrated manifold assembly to supply coolant to axial coolant channels

A stator assembly is provided that simplifies the process of coupling the stator windings to the winding lugs. The stator assembly includes a pre-fabricated connector that is attached to the stator via a plurality of stator winding terminations. The pre-fabricated connector includes a plurality of electrically conductive termination coupling members that form conductive pathways between at least a portion of the stator winding terminations and a plurality of bus bars, where each of the bus bars includes a lug. The pre-fabricated connector may also include a second plurality of electrically conductive termination coupling members that form conductive pathways between at least a second portion of the stator winding terminations and a plurality of lugless bus bars. An electrically insulating material is overlaid over portions of the connector ring, thereby preventing contact or partial discharge between the various bus bars.

Motor winding connector ring

Hybrid rotor assembly

A method of manufacturing an electric motor that includes a plurality of structural cooling features is provided, where the electric motor utilizes axial cooling channels integral to the stator teeth, thus allowing direct contact between the circulating coolant and the lamination stack. A coolant manifold assembly, incorporated into the stator between left and right stator portions, provides a means of distributing coolant to the axial cooling channels.

Motor cooling system utilizing axial cooling channels

A powertrain utilizing an active core motor with coaxially aligned planetary-differential-planetary gear assemblies is provided.

High torque and power density drive system with shortened overall width

Embodiments discussed herein refer to backwards compatible charging circuits and methods for charging a battery to a relatively high voltage level regardless of whether the charging station is capable of supplying power at that relatively high voltage level. The circuitry and methods according to embodiments discussed herein can use the motor and power electronics (e.g., inverter) to provide a voltage boosting path to increase the charge voltage from a legacy voltage level (e.g., a relatively low voltage level) to a native voltage level (e.g., a relatively high voltage level). When a native voltage charging station is charging the battery, the circuitry and methods according to embodiments discussed herein can use a native voltage path for supplying power, received from the charging station at the native voltage, to the battery.

Boost converters and methods for using an inverter and a motor

A method of cooling an electric motor is provided utilizing axial cooling channels that are integral to the stator teeth, thus allowing direct contact between the circulating coolant and the lamination stack and providing an efficient means of removing motor assembly heat. Additionally, as the coolant flows out of the cooling channels it impinges on the end windings, thereby providing a secondary means of cooling the motor assembly.

An electric motor cooling system is provided utilizing axial cooling channels that are integral to the stator teeth, thus allowing direct contact between the circulating coolant and the lamination stack and providing an efficient means of removing motor assembly heat. Additionally, as the coolant flows out of the cooling channels it impinges on the end windings, thereby providing a secondary means of cooling the motor assembly.

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Pleasanton, CA, United States of America

Emad Dlala