Gm Global Technolgoy Operations, Inc.

Mark D Korich

Mark L Selogie

David Yuang Tang

Young Mok Doo

Konstantinos Triantos

Constantin C Stancu

Gregory S Smith

Brooks S Mann

Nicholas Hayden Herron

David H Miller

Douglas S Carlson

Terence G Ward

Keming Chen

George John

Robert T Dawsey

Anthony P Tata

Erik Christopher Hatch

Karl David Conroy

Gholamreza Esmaili

Alex Thompson

Jimmy M Chang

Alan L Barry

Vicentiu Grosu

Cindy Chou

Larry A Hagerty

Yong M Doo

An electrical system includes an alternating current (AC) connector rod assembly and a polyphase electric machine. The electric machine has a plurality of phase leads each electrically connected to the AC connector rod assembly. The assembly includes spaced AC connector rods each having a center axis. The assembly also includes insulating housings and a carrier plate defining through holes that receive and space the AC connector rods. The carrier plate defines features that engage mating features of the insulating housings while allowing each of the rods to rotate about its respective center axis within the carrier plate. A vehicle includes a direct current (DC) battery pack, a DC bus, an AC bus, a PIM that is electrically connected on a first side to the DC bus and on a second side to the AC bus, the AC connector rod assembly, a traction motor, and a transmission.

Connector rod assembly for AC inverter output

A power electronic building block includes a housing; a power module mounted within the housing; a controller mounted within the housing and coupled to the power module; a capacitor assembly coupled to the power module and mounted within the housing; an AC bus bar mounted within the housing; and a DC bus bar coupling the capacitor assembly to the power module and mounted within the housing.

Scalable and modular approach for power electronic building block design in automotive applications

A power electronics assembly is provided. The assembly includes a housing defining at least one cavity and having a fluid passageway extending therethrough, the fluid passageway having first and second portions on respective first and second opposing sides of the at least one cavity, and a plurality of inductors housed within the at least one cavity of the housing such that the first and second portions of the fluid passageway are on first and second opposing sides of each of the plurality of inductors.

Power electronics assembly with multi-sided inductor cooling

A manifold is provided for supporting a power module assembly with a plurality of power modules. The manifold includes a first manifold section. The first face of the first manifold section is configured to receive the first power module, and the second face of the first manifold section defines a first cavity with a first baseplate thermally coupled to the first power module. The first face of the second manifold section is configured to receive the second power module, and the second face of the second manifold section defines a second cavity with a second baseplate thermally coupled to the second power module. The second face of the first manifold section and the second face of the second manifold section are coupled together such that the first cavity and the second cavity form a coolant channel. The first cavity is at least partially staggered with respect to second cavity.

Power module assemblies with staggered coolant channels

A filter for an automotive electrical system includes a substrate having first and second conductive members. First and second input terminals are mounted to the substrate. The first input terminal is electrically connected to the first conductive member, and the second input terminal is electrically connected to the second conductive member. A plurality of capacitors are mounted to the substrate. Each of the capacitors is electrically connected to at least one of the first and second conductive members. First and second power connectors are mounted to the substrate. The first power connector is electrically connected to the first conductive member, and the second power connector is electrically connected to the second conductive member. A common mode choke is coupled to the substrate and arranged such that the common mode choke extends around at least a portion of the substrate and the first and second conductive members.

Electromagnetic interference filter for automotive electrical systems

A power electronics assembly is provided. A first support member includes a first plurality of conductors. A first plurality of power switching devices are coupled to the first support member. A first capacitor is coupled to the first support member. A second support member includes a second plurality of conductors. A second plurality of power switching devices are coupled to the second support member. A second capacitor is coupled to the second support member. The first and second pluralities of conductors, the first and second pluralities of power switching devices, and the first and second capacitors are electrically connected such that the first plurality of power switching devices is connected in parallel with the first capacitor and the second capacitor and the second plurality of power switching devices is connected in parallel with the second capacitor and the first capacitor.

Low inductance power electronics assembly

Systems and/or methods are provided for an inverter power module with distributed support for direct substrate cooling. An inverter module comprises a power electronic substrate. A first support frame is adapted to house the power electronic substrate and has a first region adapted to allow direct cooling of the power electronic substrate. A gasket is interposed between the power electronic substrate and the first support frame. The gasket is configured to provide a seal between the first region and the power electronic substrate. A second support frame is adapted to house the power electronic substrate and joined to the first support frame to form the seal.

Inverter power module with distributed support for direct substrate cooling

A busbar assembly for an inverter module has a power module, a capacitor module with at least one capacitor, and a battery all interconnected by a busbar. The busbar includes a base busbar portion that is electrically coupled to the battery and a branch busbar portion that extends from the base busbar to the power module and that electrically connects to the capacitor module at points located between the base node and the power module.

Low inductance busbar

Power inverters include a frame and a power module. The frame has a sidewall including an opening and defining a fluid passageway. The power module is coupled to the frame over the opening and includes a substrate, die, and an encasement. The substrate includes a first side, a second side, a center, an outer periphery, and an outer edge, and the first side of the substrate comprises a first outer layer including a metal material. The die are positioned in the substrate center and are coupled to the substrate first side. The encasement is molded over the outer periphery on the substrate first side, the substrate second side, and the substrate outer edge and around the die. The encasement, coupled to the substrate, forms a seal with the metal material. The second side of the substrate is positioned to directly contact a fluid flowing through the fluid passageway.

Power inverters

A connector assembly is provided for coupling an electric motor to a power source, wherein the power source comprises a first conductive member. The connector assembly comprises a non-conductive member having an inner channel configured to receive at least a portion of the first conductive member, a second conductive member slidably disposed within the inner channel, coupled to the electric motor, and configured to be coupled to, and to receive a force having a first direction from, the first conductive member, and a spring member, retained between the non-conductive member and the second conductive member and configured to resist movement of the second conductive member in the first direction.

Connector assembly for coupling an electric motor to a power source

Systems and apparatus are provided for capacitor segments for use in a vehicle. A capacitor segment comprises an inner conductor configured to receive a first potential and having a generally L-shaped longitudinal cross-section. An outer conductor is configured to receive a second potential, and is electrically insulated from the inner conductor. The outer conductor comprises a first section having a generally L-shaped longitudinal cross-section aligned with the inner conductor, and a second section coupled to the first section and having a generally L-shaped lateral cross-section. The second section and the inner conductor define an inner region. A capacitor is located in the inner region and coupled to the inner conductor and the second section. The capacitor segment is configured such that current flows through the capacitor in a first direction, and current flows through the second section in a second direction that generally opposes the first direction.

Low inductance interconnect device for a power capacitor component

A vehicular power inverter connector assembly is provided. The assembly includes a housing, a plurality of first engagement formations on the housing shaped to mate with a plurality of inverter engagement formations on a vehicular power inverter, a plurality of second engagement formations on the housing shaped to mate with a plurality motor engagement formations on a vehicular motor, and a plurality of current sensors connected to the housing and configured to detect current flowing between the vehicular power inverter and the vehicular motor.

Power inverter connector having integrated current sensors

An inverter assembly for a vehicle includes a housing, a first inverter, and a second inverter. The housing comprises a plurality of walls. The plurality of walls form an inlet for cooling fluid to enter the housing, an outlet for the cooling fluid to exit the housing, and a channel, and a channel for the cooling fluid to flow therebetween. The first inverter is disposed within the housing proximate the channel, and is configured to be cooled by the cooling fluid flowing through the channel. The second inverter is also disposed within the housing proximate the channel, and is also configured to be cooled by the cooling fluid flowing through the channel.

Vehicle inverter assembly with cooling channels

An inverter assembly includes a housing and a substrate disposed in the housing. The substrate includes at least a first conductive layer patterned to include an alternating current (AC) path and a direct current (DC) path. A plurality of inverter switches is mounted on the substrate and electrically coupled to the AC path and the DC path.

Liquid-cooled inverter assembly

An interface assembly for an inverter of a vehicle includes an interface, a plurality of busbars, a communication medium, and a clip. The interface is for communicating with one or more vehicle systems outside of the interface assembly. The plurality of busbars are configured to receive and transport electric current. The communication medium is electrically coupled between the plurality of busbars and the interface. The communication medium is configured to provide information to the interface based at least in part on the electric current transported by the plurality of busbars. The clip assembly is electrically coupled between the plurality of busbars and the communication medium.

Growing community of inventors

Chino Hills, CA, United States of America

Mark D Korich