Ford Global Technolgoies, LLC

Fan Wang

Baoming Ge

Lihua Chen

John P Casci

Moon Young Lee

Serdar Hakki Yonak

Fan Xu

Shahram Zarei

Boris Curuvija

Yan Zhou

Shuitao Yang

Mohammed Khorshed Alam

Yantao Song

Joseph Sherman Kimmel

Abdullahi M Hajiabdi

Petros G Taskas

Miao Wang

A power inductor includes windings having a first coil defining an axially extending cavity and a core have at least first and second core segments extending axially through at least a portion of the cavity. The segments are radially spaced from each other to define a molding channel. Molding is disposed in the molding channel and configured to urge the first and second core segments radially apart such that outer surfaces of the core segments are in direct contact with inner surfaces of the coil.

Power inductor thermal management

A power inductor includes a magnetic core having first and second legs and opposing first and second curved sections, a conductor having a first coil around the first leg and a second coil around the second leg; and a fluid circuit having a first branch disposed between the first leg and the first coil and a second branch disposed between the second leg and the second coil.

Power inductor with internal cooling passages

An electrified vehicle includes an inductor having an associated arcuate deflector to redirect fluid toward inductor coils to facilitate heat transfer. The inductor may be disposed within a transmission proximate to at least one gear that distributes fluid during rotation to proximate components to provide splash lubrication. The arcuate deflector may redirect splashed fluid from between the inductor and the transmission housing toward the inductor coils. The deflector may be secured to the inductor via terminal connectors that electrically couple the inductor coils to a bus bar connected to a variable voltage converter.

Electrified vehicle inductor cooling system

A boost converter for a hybrid vehicle includes an inductor, a bus bar, an insulator, a temperature sensor, and a wire. The bus bar is configured to connect the inductor to a power source. The insulator is disposed over the bus bar and defines an array of orifices. The temperature sensor is configured to measure a temperature of the inductor. The wire is connected to the temperature sensor. The wire is weaved through the array of orifices such that the wire positionally alternates between opposing external sides of the insulator.

Power supply device system for a hybrid or electric vehicle

An automotive propulsion system has a transmission including an output shaft, a variable voltage converter including an inductor disposed within a housing of the transmission such that transmission fluid within the housing contacts the inductor to cool the inductor, and a controller that maintains a magnitude of current through the inductor to less than a limit value that is defined by a speed associated with the output shaft and a switching frequency of the variable voltage converter.

Predictive inductor cooling

A power inductor such as a variable voltage converter power inductor having a temperature sensor embedded therein is disclosed. In one or more embodiments, the sensor may be disposed between the core and the coil or winding. The sensor may be positioned in the cavity of a bobbin or the core itself.

Embedded temperature sensor solution for power inductor

A traction powertrain system of an electrified vehicle includes a power electronics module and a controller. The power electronics module, such as in the form of an inverter, is configured to drive a traction motor with power from a traction battery via a DC-link capacitor. The controller has an on-board power source, such as in the form of a super capacitor. The controller is configured to, in response to detecting an event in which the DC-link capacitor is to be discharged, use power from the on-board power source for controlling the power electronics module and control the power electronics module to operate in a manner causing the DC-link capacitor to be discharged.

Controller-based active discharge circuitry for discharging link capacitor of traction powertrain of electrified vehicle

A closed ferromagnetic housing has a pair of access ports and a center ferromagnetic post extending from and between opposite ends thereof. At least one conductor, contained within and completely surrounded by the closed ferromagnetic housing, is wound around the center ferromagnetic post such that the closed ferromagnetic housing, center ferromagnetic post, and at least one conductor form an inductor in which the ferromagnetic housing and the center ferromagnetic post define a core of the inductor and the at least one conductor defines a coil of the inductor. The access ports are configured to permit flow of coolant into the closed ferromagnetic housing and around the center ferromagnetic post to cool the at least one conductor.

Compact power inductor

A hybrid transmission has a housing with two chambers. One chamber contains electric motors and other transmission components that require a liquid lubricant and coolant such as automatic transmission fluid. The other chamber contains power electronics that must be isolated from the liquid lubricant/coolant. To reduce the number of breather tubes required, it is beneficial if air can move between the chambers. A terminal block cooperates with a separating wall between the two chambers to create a labyrinth seal between the chambers.

Transmission with vented terminal block

An inductor for a converter of an electric machine includes a core defining a channel configured to receive transmission fluid on an outer surface of the core. Coils made of windings are wrapped on the core. The windings enclose an open side of the channel to define an oil flow passage, wherein oil flowing through the oil flow passage is in direct contact with both the windings and the core to absorb heat from the windings and the core.

Variable voltage inductor with direct liquid cooling

A temperature sensor arrangement includes a housing having on opposite sides thereof a spring element and cover, and a temperature sensor lead and thermal pad such that the spring element is disposed between one of the sides and the cover, the temperature sensor lead is disposed between the other of the sides and the thermal pad, and the cover and thermal pad define opposite exterior sides of the temperature sensor arrangement. The housing carries and permits relative movement of the cover. The spring pushes the cover away from the one of the sides.

Inductor temperature sensor

A vehicle, a vehicle electronics power assembly, and a method for providing and cooling an inductor assembly are provided. The vehicle has provided with a vehicle electrical system with a variable voltage converter (VVC) and an inductor assembly with a core and a winding. A housing is provided with a first housing member and a second housing member. The first and second housing members cooperate to encapsulate the winding and at least a portion of the core of the inductor assembly. The first housing member defines a first inlet and a first outlet, and the second housing member defines a second inlet and a second outlet. A fluid system is connected to the first inlet, the second inlet, the first outlet, and the second outlet to provide pressurized fluid to the first and second inlets to circulate fluid through the housing.

Direct liquid cooled inductor

This disclosure is directed to power systems for transferring power between electrical components. An exemplary power system includes a first electrical component (e.g., an inverter system) having a current sensor assembly for detecting current flowing between the first electrical component and a second electrical component (e.g., an electric motor) in order to more reliably manage and control operation of the second electrical component. The current sensor assembly may include an integrated cooler that includes an internal cooling circuit configured to circulate coolant for cooling one or more bus bars of the current sensor assembly.

Liquid cooled current sensor assemblies

A power inductor includes a magnetic core, a conductor coiled around the core; an end cover secured to the core, a tube configured to convey fluid, and a fluid flow guide supported on the end cover. The flow guide has a receiving portion disposed under an end of the tube to receive the fluid and a distribution portion in fluid communication with the receiving portion. The distribution portion is configured to supply the fluid onto the conductor and the core and includes a plurality of guide walls.

Power inductor with cooling guide

A vehicle, a vehicle power electronics assembly, and a method of packaging and cooling an inductor assembly are provided. The vehicle has a vehicle electrical system with a variable voltage converter (VVC) and an inductor assembly. The inductor assembly has a core and a winding. A bobbin is connected to and surrounds an outer perimeter of the inductor assembly. The bobbin defines an inlet, an internal fluid passage, and a series of nozzles. The nozzles in the series of nozzles are spaced apart from one another about the bobbin and are positioned to spray fluid directly onto the winding. A fluid system is connected to the inlet to provide pressurized fluid to the inlet.

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Novi, MI, United States of America

Fan Wang