PRESSURIZED AND GRAVITY-FED LIQUID COOLING OF ELECTRIC MOTOR
Granted: August 6, 2015
Application Number:
20150222162
A liquid cooling system for an electric motor includes: a pump for liquid to cool the electric motor; a heat exchanger that removes heat from the liquid; a manifold extending above a stator of the electric motor, the manifold receiving the liquid under pressure and having a first opening that directs a first liquid jet onto the stator; and a first tray above first end turns of the stator, the manifold having a second opening that directs a second liquid jet onto the first tray, the first…
COOLING OF CHARGING CABLE
Granted: August 6, 2015
Application Number:
20150217654
A charging system for an electric vehicle includes: a power supply; a cable having first and second ends, the first end attached to the power supply, the cable comprising a charging conductor and a cooling conduit, each of which extends from the first end to the second end; and a connector attached to the second end of the cable, the connector having a form factor corresponding to a charge port of the electric vehicle; wherein the cooling conduit is adapted to convey a fluid that cools…
Electromagnetic Switch with Damping Interface
Granted: June 4, 2015
Application Number:
20150155112
An electromagnetic switch includes: a stationary electrical contact; a moveable electrical contact; an actuated member to which the moveable electrical contact is attached for driving the moveable electrical contact into and out of contact with the stationary electrical contact; and a damping interface between the moveable electrical contact and the actuated member.
Flux Shield for Electric Motor
Granted: May 7, 2015
Application Number:
20150123511
An electric motor includes: a stator; a shaft; a rotor mounted on the shaft, the rotor having an end ring that is concentric with the shaft; and a flux shield around the shaft inside the end ring.
Cell Module Assemblies
Granted: April 23, 2015
Application Number:
20150111082
A method includes: assembling a thermal-exchange tube in a module housing for an energy storage pack; assembling cells in the module housing, wherein the thermal-exchange tube runs between rows of the cells; applying an adhesive that affixes the cells and the thermal-exchange tube to the module housing; curing a first portion of the adhesive by radiation, wherein a second portion of the adhesive is shielded from the radiation by the cells or the thermal-exchange tube; and curing at least…
CONTROLLER APPARATUS AND SENSORS FOR A VEHICLE DOOR HANDLE
Granted: February 5, 2015
Application Number:
20150039180
In a vehicle door assembly, controllers processes signals from an extension force sensor and a retraction force sensor to control a door handle. As a motor retracts the handle, a swing arm in the vehicle door presses against the retraction force sensor causing the handle controller to stop the motor. Pushing on the retracted handle presses the swing arm against the retraction force sensor a second time causing the controllers to operate the motor and extend the handle. As the handle…
Air-tight Slip-on Structural Joint Not Using Sealant
Granted: December 25, 2014
Application Number:
20140376995
A method includes: assembling first and second pieces in a slip-fit joint without applying adhesive or sealant, wherein the first piece covers a portion of the second piece in the slip-fit joint; and injecting adhesive through the first piece until the adhesive fills a gap of the slip-fit joint, wherein the adhesive makes the slip-fit joint air tight without applying the sealant. An air-tight slip-fit joint consists essentially of: first and second pieces assembled without applying…
LIMITING RADIAL EXPANSION IN ROTOR BALANCING
Granted: December 18, 2014
Application Number:
20140368082
A rotor including: a shaft; a structure comprising at least one end ring and rotor bars, wherein at least the end ring comprises a material subject to expansion or movement radially outward from the shaft upon a rotor balancing process that involves spinning of the structure; a core that at least partially encloses the rotor bars; and means for limiting the expansion or movement of the structure radially outward. A method including: providing a structure comprising at least one end ring…
Location Based Charging Control System
Granted: November 27, 2014
Application Number:
20140347018
A method for automatically charging the battery pack of an electric vehicle in accordance with a set of location sensitive charging instructions is provided. Exemplary location sensitive charging instructions include preset charging schedules and preset charge level limits. Different charging schedules and different charge level limits may be preset for different charging stations and locations, thus allowing the user to preset the charging instructions for each of multiple locations…
Rotor Assembly with Electron Beam Welded End Caps
Granted: November 20, 2014
Application Number:
20140339950
A rotor assembly and a method for fabricating the same are provided in which a pair of end caps, positioned at either end of the stack of laminated discs, are fusion welded to the rotor bars using an electron beam welder, thereby yielding improved electrical and mechanical characteristics in a low weight assembly.
Folding and Stowing Rear-Facing Vehicle Seat
Granted: November 13, 2014
Application Number:
20140333086
A rear-facing seat for a vehicle comprises: a seat portion connected to the vehicle by a hinge so that the rear-facing seat assumes at least a stowed position and an unstowed position; and a back portion connected to the seat portion, wherein in the unstowed position the back portion assumes at least an up position and a down position, wherein in the up position (i) a hook on the back portion engages a first striker on a vehicle wall, and (ii) a latch on the back portion engages a second…
Self-Activated Draining System
Granted: November 13, 2014
Application Number:
20140332085
A method of managing leakage of liquid inside a battery system comprises: containing leaking liquid in a non-liquid sensitive region of the battery system so as to protect internal electrical components of the battery system from coming in contact with the leaking liquid; and in direct response to the leakage, expunging the leaking liquid from the battery system. A drain device includes: a body with a port therethrough, the body configured to be positioned in a wall of a container; means…
EXTRUSION PIECE WITH DISSIMILAR ENDS
Granted: November 6, 2014
Application Number:
20140326351
A method includes: determining a design for a longitudinal piece of a particular length, wherein first and second ends of the longitudinal piece have dissimilar shapes; extruding a piece that is at least twice the particular length, wherein a profile throughout the extruded piece has the first end shape; hydroforming the extruded piece to generate an expanded portion between ends of the extruded piece, wherein the ends retain essentially the first end shape; and cutting through the…
CONTROL SYSTEM FOR AN ALL-WHEEL DRIVE ELECTRIC VEHICLE
Granted: September 11, 2014
Application Number:
20140257613
Electric vehicles and, more particularly, a control system for an all-wheel drive electric vehicle.
FAST CHARGING OF BATTERY USING ADJUSTABLE VOLTAGE CONTROL
Granted: September 11, 2014
Application Number:
20140253023
A battery cell charger for rapidly charging a lithium ion battery cell (or string of series-parallel connected cells) having a maximum battery cell voltage the battery cell charging system including: a circuit for charging the battery cell using an adjustable voltage charging-profile to apply a charging voltage and a charging current to the battery cell wherein the adjustable voltage charging-profile includes: a first charging stage with a constant first stage charging current and an…
Battery Pack Exhaust Nozzle
Granted: July 31, 2014
Application Number:
20140212708
A thermal management system is provided that minimizes the effects of thermal runaway within a battery pack. The system includes a sealed battery pack enclosure configured to hold a plurality of batteries and at least one exhaust nozzle assembly. The exhaust nozzle assembly includes an exhaust nozzle that passes and directs the flow of hot gas from within the battery pack to the ambient environment during a thermal runaway event, a nozzle seal mounted within the exhaust nozzle that seals…
FLEXIBLE PRINTED CIRCUIT AS HIGH VOLTAGE INTERCONNECT IN BATTERY MODULES
Granted: July 31, 2014
Application Number:
20140212695
A system and method for improving on conventional techniques for connecting energy storage elements of a high-voltage battery pack. A tuned flexible printed circuit individually coupled to each electrode of each cell of a matrix of cells of the battery pack provides improved manufacturability and reliability.
POWER ELECTRONICS INTERCONNECTION FOR ELECTRIC MOTOR DRIVES
Granted: July 31, 2014
Application Number:
20140209344
The bus bar includes a first bus bar layer formed of a first generally uniform thickness of a first bus bar conductor; a first dielectric layer overlying a top surface of the first bus bar layer; and a second bus bar layer formed of a second generally uniform thickness of a second bus bar conductor overlying a top surface of the first dielectric layer and the top surface of the first bus bar layer wherein: the first bus bar layer includes a first via for receipt of a first electrical…
Battery Pack Base Plate Heat Exchanger
Granted: July 10, 2014
Application Number:
20140193683
A heat exchanger integrated into an electric vehicle's battery pack enclosure is provided, where the heat exchanger conduits are mechanically and thermally coupled to the inside surface of the enclosure base plate and where the battery pack enclosure is mounted such that ambient air flows over the outside surface of the enclosure base plate during vehicle motion. A thermal management system is coupled to, and controls operation of, the integrated battery pack heat exchanger such that in…
SYSTEM FOR ABSORBING AND DISTRIBUTING SIDE IMPACT ENERGY UTILIZING AN INTEGRATED BATTERY PACK
Granted: July 3, 2014
Application Number:
20140182958
An energy absorbing and distributing side impact system for use with a vehicle is provided, the system utilizing a battery pack enclosure that includes a plurality of cross-members that transverse the battery pack enclosure and absorb and distribute at least a portion of the load received when either the first or second side of the vehicle receives a side impact. The battery pack enclosure is positioned between the front and rear vehicle suspension assemblies and mounted between, and…
