Lear Corporation

Nadir Sharaf

Slobodan Pavlovic

Richard Joseph Hampo

Rutunj Rai

Dilip Daftuar

Reinhard Pusch

Reshma Rathod

Ajmal Imran Ansari

Aric Henderson Anglin

Aftab Ali Khan

Juan Lopez

John M Van Dyke

Yu Qin

David Menzies

Michael Hardy

Venkat Rao Yalamanchili

George Kaminski

A direct current (DC) link capacitor operable within an electrically drivable vehicle having a high-voltage battery is provided configured to facilitate output of a DC voltage to an inverter configured to process the DC voltage to facilitate powering an electric motor used to drive the vehicle. The DC link capacitor includes a housing enclosing capacitive elements configured to facilitate capacitive processing between an input and an output, at least a first pair of terminals configured to deliver the DC voltage to the input, the capacitive elements processing the DC voltage received at the input into a capacitive DC voltage, and at least a second pair of terminals configured to output the capacitive DC voltage to the inverter, the inverter relying on the capacitive DC voltage to facilitate powering the electric motor.

Power module cooling system

A housing or other enclosure used to facilitate fluid cooling of a circuitry of a battery charger, such as but not limited to a battery charger of the type used to facilitate charging a high voltage vehicle battery with AC energy provided from a utility power grid. The housing may include a groove and seal arrangement operable to seal a fluid coolant chamber used to cool the circuitry from leaking fluid during use.

Sealed battery charger housing

A cooled electric assembly includes a box that defines an interior space. An electrical conductor is located within the interior space. A cooling tube is attached to the box. A thermal conductor is located at least partially within the interior space and is in thermal contact with the electrical conductor and in thermal contact with the cooling tube.

Cooled electric assembly

A heat conductor for use with an inverter in an electric or hybrid-electric vehicle, the inverter including a direct current link capacitor having multiple film capacitors configured in a stack to form a substantially polygonal prism. Each film capacitor has orthotropic characteristics. The heat conductor has a first substantially planar member configured to contact a first side of the polygonal prism formed by one of the film capacitors, and a second substantially planar member configured to contact a second side of the polygonal prism opposite the first side of the rectangular prism, the second side of the rectangular prism formed by another one of the film capacitors. The first and second planar member are thermally conductive for dissipating heat generated by the film capacitors, are attached by an interconnect, and have sufficient rigidity to confine expansion of the film capacitors across the thicknesses thereof.

Heat conductor for use with an inverter in an electric vehicle (EV) or a hybrid-electric vehicle (HEV)

An electromagnetic device arrangement includes a transformer assembly having a core, windings, and a housing disposed around at least a portion of the core and windings. An enclosure at least partially encloses the transformer assembly. The transformer assembly is mounted to a first portion of the enclosure such that heat is transferred from the transformer assembly to the first portion of the enclosure. A second portion of the enclosure has an extension extending therefrom such that the extension is placed in thermal contact with the transformer assembly to transfer heat from the transformer assembly to the extension.

Heat dissipating electromagnetic device arrangement

A charger assembly is provided with a housing having a cavity with an opening. A cover is fastened to the housing for covering the opening. A heat transfer duct is mounted to the cover with an inlet end and an outlet end each extending through the cover. A plurality of heat sinks is mounted to the cover in contact with the heat transfer duct. A plurality of circuit board assemblies are each mounted to the cover in contact with the plurality of heat sinks.

Charger assembly with heat transfer duct

A cooling system is operable to facilitate cooling a power module or other electronic assembly. The cooling system may be configured to facilitate cooling a DC/AC inverter or other electronic assembly where two power modules may be arranged in an opposing relationship relative to a coolant passageway. The opposing relationship may be suitable to minimizing a packaging size and footprint required to facilitate interacting both power modules with the coolant flow.

An electrical connector includes a connector body and at least two electric terminals. A fuse is supported on the connector body and at least one of the electric terminals is supported by the fuse.

Connector with integrated fuse

A coldplate for use with electronic components in an electric vehicle (EV) or a hybrid-electric vehicle (HEV). The coldplate includes a main portion having multiple raised features on a surface thereof. The raised features are configured for attaching the main portion to a printed circuit board having multiple electronic components attached thereto. The raised features are further configured for maintaining the printed circuit board in a spaced relation relative to the main portion to facilitate air flow between the printed circuit board and the main portion for dissipating heat generated by the plurality of electronic components. The coldplate also includes a protrusion extending from the surface of the main portion. The protrusion is configured for contacting one of the plurality of electronic components attached to the printed circuit board for dissipating heat generated by the electronic component.

Coldplate for use in an electric vehicle (EV) or a hybrid-electric vehicle (HEV)

A coldplate for use with an inverter in an electric vehicle (EV) or a hybrid-electric vehicle (HEV). The inverter includes a direct current (DC) link capacitor comprising multiple film capacitors configured in a stack. The coldplate includes a first portion configured for attachment to at least one electronic component, the first portion having a perimeter and for dissipating heat generated by the electronic component. The coldplate includes a second portion oriented along the perimeter of the first portion and forming a conduit, the conduit having a chamber extending from the perimeter of the first portion and between two of the plurality of film capacitors of the DC link capacitor. The conduit has an inlet and an outlet to facilitate circulation of a coolant through the chamber of the conduit for dissipating heat generated by the DC link capacitor.

Coldplate for use with an inverter in an electric vehicle (EV) or a hybrid-electric vehicle (HEV)

An electromagnetic interference shield assembly is provided with a first housing formed of a first conductive polymer. The first housing has a cavity sized to receive an electronic sub-assembly therein. A second housing is formed of a second conductive polymer. The second housing has a cavity sized to receive the first housing therein.

Charger assembly and electromagnetic interference shield assembly

A housing assembly to enclose an electrical subassembly includes a housing formed from a conductive polymer. The housing has a cavity sized to receive an electronic sub-assembly therein. A conductive boss is insert-molded into the housing in conductive contact with the housing. A conductive bracket is fastened to the boss in conductive connection with the boss and the housing to support and electrically ground the housing.

Housing assembly to enclose and ground an electrical subassembly

In at least one embodiment, a vehicle power module comprises a first printed circuit board (PCB) including a first plurality of electrical components for providing a first voltage and a second voltage. The vehicle power module further comprises a second PCB including a second plurality of electrical components, the second PCB being spaced away from the first printed circuit board and a first connector assembly being coupled to the first PCB and to the second PCB for providing the first voltage to the second PCB. The vehicle power module further comprises a second connector assembly being coupled to the first PCB and to the second PCB for providing the second voltage to the second PCB. The first connector assembly provides the first voltage of up to 14V and the second connector assembly provides the second voltage of 200V or greater.

Printed circuit board connection assembly

An automotive power converter may include a cold plate, a printed circuit board spaced away from the cold plate and including at least one heat generating electrical component attached thereto, and another printed circuit board disposed between the cold plate and the printed circuit board spaced away from the cold plate. The converter may further include at least one thermally conductive element configured to provide a thermally conductive path from the at least one heat generating electrical component to the cold plate. The at least one thermally conductive element may pass through the printed circuit boards.

Growing community of inventors

Bloomfield Township, MI, United States of America

Nadir Sharaf