Ford Global Technolgoies, LLC

Moon Young Lee

Baoming Ge

Fan Wang

John P Casci

Lihua Chen

Serdar Hakki Yonak

Vincent T Skalski

Boris Curuvija

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

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

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 electric motor), a second electrical component (e.g., an inverter system), and a terminal block assembly adapted to electrically couple the first and second electrical components. The terminal block assembly includes an internal cooling channel configured to receive coolant for providing direct liquid cooling of the bus bar.

Liquid cooled terminal block assemblies

An electrified vehicle thermal management system includes, among other things, a transmission, an inverter, and a terminal block disposed between the transmission and the inverter. The terminal block includes a conduit configured to deliver transmission fluid from the transmission to the inverter. An electrified vehicle thermal management method includes circulating a transmission fluid between a transmission, a terminal block, and an inverter, and using the transmission fluid to manage thermal energy within the inverter.

Electrified vehicle thermal management system and thermal management method

An inductor for a boost converter in a hybrid vehicle includes a core, a coil winding, and an end cap. The coil winding is disposed about the core. The end cap is disposed over a first end of the inductor, overhangs the coil winding, defines a channel that is configured to receive fluid from a pump, defines at least one nozzle that is configured to direct fluid from an overhanging portion of the end cap and onto the coil, and defines a fluid reservoir that is in fluid communication with the channel and the at least one nozzle.

Growing community of inventors

Livonia, MI, United States of America

Moon Young Lee