Ford Global Technolgoies, LLC

Ford Motor Company Limited

Xiaogang Zhang

Jianwen James Yi

Steven Wooldridge

Mark Meinhart

Daniel Joseph Styles

Brad Alan VanDerWege

Joseph F Basmaji

Keith Michael Plagens

Peter Charles Moilanen

Neal James Corey

David Born

James Yi

Jack Adams

Joseph Norman Ulrey

Thomas George Leone

Paul Matthew Laing

John Edward Hedges

Claudia Olivia Iyer

Gary Alan Coulson

Wen Dai

Sangjin Hong

Gregory McConville

William Charles Ruona

Julia Helen Buckland

Michael Damian Czekala

Eric Warren Curtis

Paul Joseph Tennison

David John Kubinski

David Charles Weber

Harold Huimin Sun

Patrick Matthews

Steven Schwochert

David Bruce Reiche

George Aristidis Papaioannou

Ray Host

Bradley Alan Boyer

Cindy Zhou

Lynn Aimee Chesney

Thomas Polley

Clayton Mikush

Richard K Werth

Chee Haw Chan

Vidhushekhar Vasant Zambare

Jennifer Fischer

Shengqi Wu

A battery pack venting assembly includes a battery pack vent that communicates a flow of vent byproducts from a battery pack. The battery pack vent has a coolant passage that communicates a coolant to manage thermal energy levels within the flow of vent byproducts. The coolant can be a liquid coolant. The battery pack vent can be configured to communicate the flow to impinge on areas of the battery pack vent.

Battery pack venting assembly and venting method

A heat exchanger includes a housing. The housing defines a refrigerant inlet, a refrigerant outlet opposing the refrigerant inlet, at least one coolant inlet, and at least one coolant outlet. A gyroid structure is disposed within the housing. The gyroid structure defines a set of refrigerant channels that direct refrigerant through the gyroid structure, a first set of coolant channels that direct coolant through a first region of the gyroid structure, and a second set of coolant channels that direct coolant fluid through a second region of the gyroid structure. A valve is disposed within the refrigerant inlet. The valve is configured to direct refrigerant fluid to at least one of the first region and the second region of the gyroid structure.

Vehicle heat exchanger

A battery chiller for a vehicle includes a housing having a first inlet, a second inlet opposing the first inlet, a first outlet having a toroid structure surrounding the second inlet, and a second outlet having a toroid structure surrounding the first inlet. A lattice is disposed within the housing defining a first plurality of channels and a second plurality of channels. The lattice defines a first inlet duct in fluid communication with the first inlet and the first channels, and a second inlet duct in fluid communication with the second inlet and the second channels. A first flow path is defined from the first inlet, through the first inlet duct, through the first plurality of channels and to the first outlet, and a second flow path is defined from the second inlet, through the second inlet duct, through the second plurality of channels and to the second outlet.

Vehicle heat exchange

A heat exchanger includes a housing. A first cooling block is defined within the housing. The first cooling block includes a coolant inlet, a refrigerant inlet, and a first gyroid structure that defines a first set of coolant channels and a first set of refrigerant channels. A second cooling block is defined within the housing. The second cooling block includes a coolant outlet, a refrigerant outlet, and a second gyroid structure that defines a second set of coolant channels and a second set of refrigerant channels. A perforated barrier plate is interposed between the first cooling block and the second cooling block. The first set of coolant channels is in fluid communication with the second set of coolant channels via perforations in the barrier plate. The first set of refrigerant channels is in fluid communication with the second set of refrigerant channels via perforations in the barrier plate.

Advanced vehicle heat exchanger

A varnish injection system for an electric motor includes a pair of varnish injection assemblies and a biasing device. Each varnish injection assembly includes an injector arm and a varnish injector nozzle attached to the injector arm and operable to provide a varnish to a gap defined between the stator core and one or more wires among the plurality of wires. The biasing device connects the pair of varnish injection assemblies and is configured to exert a compressive force urging the pair of varnish injection assemblies toward each other.

Varnish application system for electric motor

A traction battery pack assembly includes an enclosure having compartments and battery arrays. Each battery array is disposed in one of the compartments. An intake manifold delivers air to the compartments. An exhaust manifold receives air from the compartments. A thermal management method includes using an intake manifold to deliver air to compartments within an enclosure. The compartments each house at least one battery array. The method includes using an exhaust manifold to receive air from the compartments and to communicate air from the enclosure.

Traction battery pack having compartmentalized battery arrays and thermal management method for same

A varnish application system includes an electric motor, a clamp, and a varnish injector. The clamp includes a beam, a first end plate fixed to the beam and engageable to a first end of the electric motor, and a second end plate releasably connected the beam and engageable to a second end of the electric motor. The varnish injector is arranged to apply varnish to the electric motor when the clamp engages the electric motor.

Varnish applicator for electric motor

A method for applying varnish to an electric motor includes locating a varnish injector above a slot of a stator of the electric motor, depressing an intermediate layer in the slot with the varnish injector, and applying varnish from the varnish injector into a gap defined between the intermediate layer and a wall of the slot.

Varnish injector for motor

An electric machine includes a plurality of laminations stacked to form a stator defining an end face and a plurality of slots spaced about a circumference of the stator. The electric machine further includes a plurality of inserts each disposed, and bonded to a portion of the end face, between an adjacent pair of the slots, and each defining an outer triangular-shaped tip that is radially outside the adjacent pair of the slots. The electric machine further includes end windings extending out from the adjacent pair of the slots and bent over a corresponding one of the inserts such that the end windings engage the corresponding one of the inserts and exert a compression force on the corresponding one of the inserts and the laminations.

Electric machine insert device

An e-machine that provides propulsion and regenerative braking includes a rotor and a stator that includes pin conductors encircling the stator. Current is conducted around the stator for a plurality of phases of alternating current. Phase terminals and neutral terminals are connected by terminal connectors to a plurality of wires that connect to the neutral terminal or connect the phase terminals to a source of alternating current. The terminal contacts include means for dampening vibration disposed adjacent terminals. The means for dampening vibration may include a spiral segment of the wire that encircles the terminal or the spiral segment may be disposed adjacent the terminal. A flexible joint assembly may be a clamp including a terminal contact that is movable on ball bearings between an upper jaw and a lower jaw. Another flexible joint assembly may include a receptacle that receives a plug supported on ball bearings.

Method to improve e-machine durability

An electric motor includes a stator, an insulating layer, and a wire. The stator includes a first circular laminate and a second circular laminate. The first laminate includes a first finger having a distal end extending toward a center point of the first circular laminate. The second laminate includes a second finger having a distal end extending toward a center point of the second circular laminate. The first and second fingers define a wall. The distal ends of the first and second fingers define a space therebetween. The insulating layer extends along the wall and into the space. The insulating layer is spaced from the distal end of the second finger. The wire extends along the insulating layer below the distal ends of the first and second fingers.

Systems and methods for cold starting an internal combustion engine are described. In one example, fuel is delivered in four equal amounts into a cylinder during a cycle of the cylinder. The fuel is injected so as to reduce cylinder wall wetting, raise combustion stability, and increase exhaust system heating.

Methods and system for engine cold starting

A varnish injection system includes a varnish injector including a base, a nozzle extending from the base, and a spacer disposed on the nozzle, and an electric motor including a stator, a wire, and an insulating layer between the stator and the wire. The nozzle is arranged to deposit varnish between the stator and the insulating layer. The nozzle and the stator define a gap therebetween when the spacer engages the stator.

Systems and methods for cold starting an internal combustion engine are described. In one example, the two amounts of fuel are injected into an engine cylinder during a cycle of the engine cylinder. The first amount of fuel is combusted to generate torque to rotate a crankshaft of the engine and the second amount of fuel is at least partially combusted in an exhaust system of the engine to increase exhaust gas temperature.

Method and system for starting an engine

Methods and systems are provided for reducing emissions during an engine cold start. In one example, a method may include, during emission control device heating, injecting heated air into an exhaust runner of each cylinder of the engine during an exhaust stroke of the corresponding cylinder, after a blowdown exhaust pulse. In this way, an amount of hydrocarbons in feedgas provided to the emission control device prior to the emission control device reaching its light-off temperature may be reduced.

Systems and methods for hot air injection into exhaust ports

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Novi, MI, United States of America

Xiaogang Zhang