BorgWarner

A multi-level inverter configured to convert DC power to AC power to drive a motor includes a first printed circuit board for a two-level inverter, a power module electrically connected to the first printed circuit board; one or more busbars, one or more extension capacitors electrically connected to the one or more busbars, and a second printed circuit board electrically connected to the power module and to the first printed circuit board, wherein the second printed circuit board includes: one or more extension switches electrically connected to the one or more busbars, and one or more extension controllers to control the one or more extension switches.

A system includes an inverter configured to convert DC power from a battery to AC power to drive a motor, wherein the inverter includes: a galvanic isolator separating a high voltage area of the inverter from a low voltage area of the inverter; a low voltage controller in the low voltage area; and a high voltage controller in the high voltage area and configured to communicate with the low voltage controller via the galvanic isolator, wherein the galvanic isolator includes: a printed circuit board (PCB) including a substrate having a high voltage side defining the high voltage area and a low voltage side defining the low voltage area, a low voltage metal trace on the low voltage side of the substrate and connected to the low voltage controller, and a high voltage metal trace on the high voltage side of the substrate and connected to the high voltage controller.

A power converter includes a first half-bridge configured to operate at a first frequency, a second half-bridge in parallel with the first half-bridge and configured to operate at the first frequency, a third half-bridge in parallel with the second half-bridge and configured to operate at the first frequency, and a neutral half-bridge of the power converter in parallel with the third half-bridge and configured to operate at a second frequency, wherein the second frequency is based on the first frequency.

A DC-DC converter includes a first switch, and a first diode in parallel with the first switch, a second switch, and a second diode in parallel with the second switch, a third switch, and a third diode in parallel with the third switch, a fourth switch, and a fourth diode in parallel with the fourth switch, and one or more controllers configured to operate in a first period to turn on the first switch and hold the fourth switch to remain turned off, and to turn on the third switch and hold the second switch to remain turned off during one or more of a synchronous rectification of the DC-DC converter, a discontinuous conduction or light load of the DC-DC converter, or a freewheeling of the DC-DC converter.

The present disclosure relates to an electric compressor module (100) for a thermal management system of an electric vehicle. The electric compressor module (100) comprises a housing (110), an electric compressor (120), a heater (130), control electronics (140) and electric connectors (150). The housing (110) includes a compressor housing section (112) and a control housing section (114). The electric compressor (120) has a rotation axis (120a) along an axial direction (2). The electric compressor (120) is arranged in the compressor housing section (112). The heater (130) comprises a heating element (132) and a coolant channel (134) including coolant ports (136). The control electronics (140) comprises a circuit board (142). The electric connectors (150) are electrically connected to the control electronics (140). The heater (130) and the control electronics (140) are arranged within the control housing section (114). The control housing section (114) is arranged axially adjacent to the compressor housing section (112). The coolant ports (136) and the electric connectors (150) are arranged at the control housing section (114) and are oriented in the same direction.

A system includes a multi-level inverter configured to convert DC power to AC power to drive a motor, wherein the multi-level inverter includes: a first printed circuit board for a two-level inverter; a power module electrically connected to the first printed circuit board; and a second printed circuit board electrically connected to the power module and to the first printed circuit board, wherein the second printed circuit board includes: one or more switches; one or more capacitors electrically connected to the one or more switches; and one or more controllers to control the one or more switches.

A system includes an inverter to convert DC power from a battery to AC power to drive a motor, wherein the inverter includes: a power module including: a positive DC power tab; a negative DC power tab; an AC power tab; a first neutral power tab; a second neutral power tab, wherein the first neutral power tab and the second neutral power tab are on opposite sides of the positive DC power tab and the negative DC power tab; a first switch electrically connected to the positive DC power tab and the AC power tab; a second switch electrically connected to the negative DC power tab and the AC power tab; and one or more switches electrically connected to the AC power tab and one or more of the first neutral power tab or the second neutral power tab.

A range extender system may include a first electric machine. A range extender system may include a first gearbox. A range extender system may include an engine. A range extender system may include a first connector to couple and decouple the first electric machine to and from the engine. A range extender system may include a second connector to couple and decouple the first electric machine to and from the first gearbox.

A system includes an inverter configured to convert DC power from a main battery to AC power to drive a motor, wherein the inverter includes a galvanic isolator separating a high voltage (HV) area from a low voltage (LV) area, a gate driver in the HV area, the gate driver to control one or more switches in the HV area in response to a control signal from the LV area, an auxiliary battery assembly in the HV area, and a power supply to provide power to the HV area from each of the main battery and the auxiliary battery assembly.

A system includes a power conversion unit, wherein the power conversion unit includes: a power module; and a first cooling module configured to extract heat from the power module, wherein the power module includes: a printed circuit board; a switching power device embedded within the printed circuit board; and a first external isolation layer external to the printed circuit board, wherein the first cooling module directly contacts the first external isolation layer.