Gm Global Technolgoy Operations, Inc.

Kestutis A Sonta

Anthony M Coppola

Alireza Fatemi

Derek F Lahr

Alan G Holmes

Qigui Wang

Huaxin Li

Elisabeth Jane Berger

Daniel J Wilson

Ming Liu

Yi Liu

Gayatri Vyas Dadheech

Xiaosong Huang

Ingrid A Rousseau

Bhavesh Shah

Teresa J Rinker

Megan E McGovern

Yew Sum Leong

Jeffrey Jose Calderas

James W Boswell, Iii

A conductive cable for a battery electric vehicle is provided. The conductive cable comprises a plurality of first members in alignment to define a longitudinal axis of the conductive cable. Each first member comprises a first conductive wire about which a first outer layer is disposed for electric current to flow therethrough relative to the longitudinal axis. The first outer layer comprises a first metal substrate having a first side and an opposite second side. The first outer layer comprises a first copper-graphene (Cu-Gr) multilayer composite disposed on the first side and a second Cu-Gr multilayer composite disposed on the second side of the first metal substrate. Each first conductive wire comprises a first metallic material. The plurality of first members is disposed together along the longitudinal axis to define a cable bundle. The conductive cable further comprises a non-conductive layer disposed about the cable bundle.

Conductive cable for a battery electric vehicle

A conductive composite stator unit for an electric motor of a vehicle is provided. The stator unit comprises a stator core comprising a body having a first core end and an opposing second core end. The stator unit further comprises a plurality of conductive bars extending from the first core end to the second core end. Each conductive bar comprises a straight portion disposed in one of the slots such that the respective conductive bar is in contact with the stator core. Each conductive bar comprising a central portion and an outer layer disposed thereabout for electrical current to flow therethrough relative to the longitudinal axis, the outer layer comprises at least two copper-graphene (Cu-Gr) layers. Each Cu-Gr layer comprises a copper layer and a graphene layer. The stator unit further comprises an insulator layer disposed about each of the plurality of conductive bars.

Conductive composite stator unit for an electric motor of a vehicle

A rotor assembly for a permanent magnet motor includes a first assembly including a first plurality of laminations and a second assembly including a second plurality of laminations. The first assembly is located radially inside of the second assembly. The first assembly and the second assembly define a first opening therebetween. First and second permanent magnets are located in the first opening. Polymeric material surrounds the first and second permanent magnets in the first opening. An outer layer surrounds the rotor assembly.

Bridgeless and webless rotor assembly using polymer composites

A rotor for an electric machine includes a rotor body formed from a plurality of stacked laminations defining a first axial end and an opposing second axial end. Each of the plurality of stacked laminations includes a plurality of openings that are aligned so as to define a plurality of passages through the rotor body. A plurality of reinforcement elements extend through the plurality of stacked laminations. Each of the plurality of reinforcement elements is arranged in a corresponding one of the plurality of passages and includes a first end portion and a second end portion. The first end portion and the second end portion of select ones of the plurality of reinforcement elements extend outwardly of the first axial end and the second axial end.

Reinforced rotor for an electric machine

A rotor for an electric machine includes a rotor assembly having an outer surface and including a plurality of poles with permanent magnets. A solid layer is formed on the outer surface of the rotor assembly and has an outer surface with a first coefficient of friction that is lower than a second coefficient of friction of the outer surface of the rotor assembly. The rotor includes an outer sleeve. The rotor assembly is press-fit into the outer sleeve.

Rotor assembly with solid low friction layer and press-fit sleeve

An adhesive-reinforced rotor for a rotary electric machine includes rotor lamination layers ('rotor lams') having axial inner surfaces collectively defining rotor openings through the rotor lams. The rotor also includes reinforcement blocks disposed within a respective one of the rotor openings. A polymer primer/adhesive layer of the rotor having a bond line thickness of less than 1 mm is disposed between the one or more reinforcement blocks and the axial inner surfaces of the rotor lams. The reinforcement blocks and the primer/adhesive layer each have a tensile strength of at least 50 MPa. A modulus of elasticity of the reinforcement blocks is at least three times greater than that of the materials of the polymer primer/adhesive layer. A method of constructing an adhesive-reinforced rotor is also described herein.

Rotary electric machine with adhesive-reinforced rotor

Methods for manufacturing a pouch-type battery cell include disposing one or more electrode pairs between a first aluminum pouch layer and a second aluminum pouch layer, sealing the first pouch layer and the second pouch layer to form a peripheral seal joining the first pouch layer and the second pouch layer to form a pouch with an outer edge encasing the anode and the cathode, applying a photocatalytic polymer coating precursor to the outer edge of the pouch, and photo-curing the photocatalytic polymer coating precursor to form a conformal edge coating. The photocatalytic polymer coating precursor includes one or more photo-initiators, one or more acrylates, and one or more polyamines. The polyamines can include tertiary amines including &#x3b1;-CH functional groups, diamines represented by the formula H2N&#x2014;R&#x2014;NH2, wherein R represents saturated and unsaturated aliphatic moieties, and N,N'-(2,2-dimethylpropylidene) hexamethylenediamine. The photo-initiators can include Diphenyl(2,4,6-trimethylbenzoyl) phosphine oxide, 2,2-Dimethoxy-2-phenylacetophenone, and p-tert-butylphenyl 1-(2,3)-epoxy)propyl ether.

Methods for manufacturing a pouch-type battery cell having polymeric conformal edge coatings

Presented are electronic power module assemblies with direct-cooling vapor chamber systems, methods for making/using such power module assemblies, and vehicles equipped with such power module assemblies. A power module assembly includes an outer housing with an internal coolant chamber that circulates therethrough a coolant fluid. A power semiconductor switching device is mounted to the module's housing, separated from the coolant chamber and isolated from the coolant fluid. The power device selectively modifies electric current transmitted between a power source and an electrical load. A two-phase, heat-spreading vapor chamber device includes an outer casing with a casing segment that is mounted to the module housing, fluidly sealed to the internal coolant chamber and exposed to the coolant fluid. Another casing segment includes an inboard-facing casing surface that is mounted to an outboard-facing surface of the power device, and an outboard-facing casing surface mounted to an inboard-facing surface of the power device.

Electronic power module assemblies and control logic with direct-cooling vapor chamber systems

Presented are electronic power module assemblies with direct-cooling heat pipe systems, methods for making/using such power module assemblies, and vehicles equipped with such power module assemblies. A power module assembly includes an outer housing with an internal coolant chamber that circulates therethrough a coolant fluid. A sidewall of the module's housing defines therethrough multiple coolant windows that fluidly connect to the coolant chamber. A power semiconductor switching device is mounted to the module housing, fluidly sealed to a first coolant window with the power device's inboard surface exposed to the coolant fluid. The power device is operable to modify electric current transmitted between a power source and an electrical load. A heat pipe with an outer casing has a first casing segment thereof mounted to an outboard surface of the power device, and a second casing segment fluidly sealed to a second coolant window and exposed to the coolant fluid.

Electronic power module assemblies and control logic with direct-cooling heat pipe systems

An example of a thermal composite includes a substrate, a primer layer, a first adhesive layer, a blanket layer, a second adhesive layer, and a metal layer. The blanket layer includes basalt fibers or glass fibers. The thermal composite may be incorporated into a battery pack as a battery enclosure.

Thermal composite

A lap belt pretensioner for a lap belt configured to secure an occupant of a vehicle seat includes a pyrotechnic device. The pyrotechnic device is configured to generate a force directed to tension the lap belt around the occupant and emit an exhaust gas including particulates at high pressure and high temperature as a byproduct of the generated force. The lap belt pretensioner also includes a housing configured to retain the pyrotechnic device and defining an exhaust passage configured to expel the exhaust gas from the lap belt pretensioner. The lap belt pretensioner additionally includes a shield arranged over the exhaust passage and configured to collect and/or deflect the emitted particulates and dissipate heat energy thereof. A vehicle having the vehicle seat mounted to the vehicle structure and employing the seatbelt system is also provided.

Seatbelt pretensioner shield and heat energy dissipator

A battery enclosure comprising a support and a cover fabricated from a thermoset or thermoplastic polymer reinforced by at least a woven fabric reinforcement is described. In an embodiment the reinforcement is a woven glass fabric.

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Troy, MI, United States of America

Kestutis A Sonta