BorgWarner Inc.

Development of novel motor architectures beyond traditional radial flux designs, including linear, axial, or multi-armature configurations, often to optimize for specific performance characteristics like torque density or form factor.

Manufacturing processes and techniques for producing stator cores, windings, and coils, including lamination, impregnation, hairpin winding, and segment coil bending, to improve motor efficiency, power density, or reliability.

Methods and components for optimizing the performance, efficiency, and control of electric motors, inverters, and power converters within electric vehicle and hybrid vehicle drivetrains.

Addresses the design and arrangement of electric motors, transmissions, and associated power electronics (like inverters) to form integrated drive units for hybrid or electric vehicles, including specific components like busbars and electric brakes.

Integration of electric machines, energy storage, and power transfer systems with gas turbine engines to enable hybrid operation, electric starting, or auxiliary power generation, improving efficiency or operational flexibility.

Systems and methods for real-time or periodic assessment of turbine engine health, including detection of wear, damage, unbalance, or deterioration, to enable predictive maintenance and extend operational life.

Methods and circuits for controlling the power electronic converters (inverters, bridges) that supply current and voltage to electric motors, including switching strategies, voltage command generation, and multi-phase configurations.

Techniques and structures within heat exchangers designed to enhance heat transfer efficiency by controlling and optimizing fluid flow, including baffle arrangements, jet impingement, and condensate management.

Assemblies and components designed for reliable and efficient transfer of rotational or axial forces between mechanical parts, accommodating misalignment or specific motion profiles.

Focuses on optimizing the geometry, structure, and internal flow channels of impellers, blades, and housings to improve fluid dynamics, efficiency, or specific performance characteristics of centrifugal pumps and fans.

Methods and components for converting power into mechanical motion to drive pump mechanisms, encompassing electric motors, hydraulic actuators, and specialized motion converters like ball screws or solenoids.

Novel designs or control strategies for clutches, including one-way, centrifugal, or disconnect types, to manage torque transmission in powertrains and other mechanical systems.

Systems designed to manage the temperature of multiple components in electric or hybrid vehicles, such as batteries, electric motors, power electronics, and the passenger cabin, often using shared or interconnected cooling/heating circuits.

Support systems for gas turbine engines, including specialized pumps, cleaning methods for engine components, mobile power generation units, and specific structural components like joints and fasteners.

Pumps and blowers specifically adapted or designed for unique fluid types, challenging environments, or particular industrial, medical, or consumer applications, often involving debris, specific gas mixtures, or precise delivery requirements.

Technologies for efficiently delivering power to electric vehicles, encompassing fast charging, wireless charging, and smart grid integration, alongside vehicle-side control and management of the charging process.

Novel configurations and materials for gears and drivetrain components, including specialized profiles, self-aligning features, damping elements, and complex gear train arrangements like planetary, cycloidal, or strain wave gearing.

Focuses on novel circuit configurations for DC-DC, DC-AC, or AC-DC conversion, often involving resonant operation, multi-level structures, or switched capacitors to improve efficiency, power density, or voltage conversion ratios.

Designs and components for efficiently supplying, collecting, and managing lubricants (oil, grease) within gearboxes and transmissions to reduce friction, dissipate heat, and extend component operational life.

Integration of electric motors into larger systems (e.g., vehicles, power tools) and safety features for high-voltage components, including control interfaces, mechanical integration, and environmental protection (e.g., waterproofing).

Integration of power converters with energy storage devices (batteries, supercapacitors) or grid interfaces, often involving AC/DC conversion, power flow management, and fault handling for hybrid power systems or specific applications like EVs or PV.

Strategies and circuits for optimizing the supply and consumption of electrical power for motors, including current limiting, regenerative energy handling, battery integration, and managing power quality.

Innovations in the design, materials, and maintenance of seals, valves, and related components to improve durability, reduce leakage, and enable specific pump functions like high-pressure operation or automated seal replacement.

Techniques for determining the rotor position, speed, or other operational parameters of an electric motor without dedicated physical sensors, often relying on back-EMF, current, or voltage measurements.

Sophisticated software or hardware-implemented control strategies that optimize motor performance, such as precise speed/torque regulation, vibration reduction, or efficiency, often using model-based, predictive, or adaptive techniques.

Methods and systems for identifying anomalies, failures, or impending issues within electric motors or their associated drive and power management circuits, often by monitoring electrical or operational parameters.

Combustor and fuel supply system designs that enable operation with multiple fuel types (e.g., conventional, ammonia, hydrogen) or optimize fuel-air mixing for improved efficiency, reduced emissions, or specific power cycles.

Transmissions designed to provide a continuous range of gear ratios between fixed limits, often employing ball-planetary, toroidal, or belt-pulley mechanisms, and including their control systems for stable operation in various directions.

Focuses on the development and application of novel materials, coatings, and manufacturing processes to improve the performance, durability, and cost-effectiveness of turbine engine components.

Techniques and circuits designed to regulate output, manage input variations, mitigate resonance, or ensure stable operation of power converters under diverse load and source conditions. This includes adaptive, predictive, or fault-tolerant control schemes.

Methods and structures for integrating and enclosing electronic components into compact, multi-functional modules, often involving embedded components, multi-layer substrates, and electromagnetic shielding for performance and miniaturization.

Manufacturing processes and material compositions for creating electronic circuits on flexible or conformable substrates, enabling novel form factors, enhanced durability, and new applications beyond rigid PCBs.

Design and assembly of power conversion, distribution, and protection modules, focusing on compact form factors, efficient electrical connections, and robust protective measures for electronic systems, often in high-power applications.

Software, algorithms, and associated hardware for monitoring, controlling, and optimizing battery performance, safety, and lifespan, including charge/discharge cycles, thermal regulation, and system integration.

Focuses on the structural integrity, housing, mounting, and physical integration of battery cells into robust and protected packs within electric vehicles, including manufacturing considerations.

Design and control of power supply architectures that combine multiple power sources (e.g., AC grid, DC battery, generators) or modular battery units, often featuring switching, conversion, and redundancy for enhanced reliability and flexibility.

Systems and methods for monitoring, regulating, and diagnosing the performance and health of pumps and fans, including speed control, flow rate management, abnormality detection, and safety mechanisms like overspeed safeguards.

Methods and materials used to construct robust and protective enclosures for electronic devices, focusing on structural integrity, impact resistance, thermal dissipation, and specialized material properties for enhanced durability.

Development and processing of metal powders with specific magnetic properties, including soft magnetic alloys, permanent magnet materials, and insulated powders for electronic components, often involving precise control of particle size, morphology, and composition.