BorgWarner

A system includes: an alternating current (AC) to direct current (DC) converter (AC-DC converter) connectable to a load; a DC to DC converter (DC-DC converter) connected to the AC-DC converter and connectable to a battery; and one or more controllers including a current limiting compensator to control an operation of the AC-DC converter to control a voltage from the battery to the load.

Disclosed is a heater rod comprising a tube housing, a ceramic heating resistor (5), a contact sheet (4) electrically contacting the heating resistor (5), and a dielectric (3) electrically isolating the contact sheet (4) from the tube housing, wherein the tube housing is formed by two half-shells (2), each half-shell (2) comprising opposing lateral sections and a main section connecting the lateral sections. On opposite sides of the tube housing, a part of the lateral section of one of the two half-shells (2) is on the inside of the tube housing and a part of the lateral section of the other half-shell (2) is on the outside of the tube housing. Also disclosed is a method for manufacturing a heater rod.

A system includes a power converter, wherein the power converter includes: a first power module; and a cooling module configured to extract heat from the first power module, wherein the cooling module includes: a first heatsink plate with a connector; and a second heatsink plate with an extruded connector, wherein the extruded connector of the second heatsink plate is laser welded to the connector of the first heatsink plate.

A system for a power converter includes a rectifier, a capacitor connected to the rectifier, a direct current to alternating current inverter (DC-AC inverter) connected to the capacitor, and a switch to operate in a first position to connect a motor to an AC side of the DC-AC inverter and disconnect the motor from an AC side of the rectifier, and a second position to connect the motor to the AC side of the rectifier and disconnect the motor from the AC side of the DC-AC inverter.

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.