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An ORNL invention proposes using 3D printing to make conductors with space-filling thin-wall cross sections. Space-filling thin-wall profiles will maximize the conductor volume while restricting the path for eddy currents induction.

A Family of Integrated On-board Charger for Single and Dual Motor based Electric Vehicle Power Train
The invention aims to reduce the cost, weight and volume of existing on-board electric vehicle chargers by integrating power electronic converters of the chargers with the traction inverter.

New demands in electric vehicles have resulted in design changes for the power electronic components such as the capacitor to incur lower volume, higher operating temperatures, and dielectric properties (high dielectric permittivity and high electrical breakdown strengths).

Current battery materials such as silicon suffer from poor ion and electron transport due to non-optimal wiring. This invention facilitates particle interconnectedness to facilitate ion motion and electron transport overcoming poor assembly.

This invention describes a new combustion synthesis route to produce high purity, high performance DRX cathodes for next-generation Li-ion batteries.

A new, simpler power module and manifold design shows lower weight and volume, which allows higher power density compared with current state of the art.

Adhesives for metal parts typically are liquid-based which require complex processing. This technology is a hot melt adhesive that is mixed and applied in a solid form and after the heating and cooling cycle creates strong bonds with the substrates in a matter of seconds.

Wind or hydro power are predominantly large-scale with giant generators to convert wind or water captured by turbines into electricity. But residential-sized wind turbines could generate power for a whole house.

There is a strong drive to improve the electrical performance of a power module for power electronics applications including transportation, buildings, renewables, and power delivery.

The co-processing of cathode and composite electrolyte for solid state polymer batteries has been developed. A traditional uncalendared cathode of e.g.