Method and apparatus for the external application of a battery pack adhesive
Granted: March 5, 2013
Patent Number:
8389142
A method and apparatus for simplifying battery pack assembly that allows inspection of the cell-to-housing bonding region is provided. In particular, a battery pack housing member is provided that includes an interior surface that partially defines the interior region of the battery pack and that includes a plurality of cell mounting wells and an exterior surface that includes a plurality of bonding wells. Adhesive introduced into the bonding wells forms a mechanical bond between an…
Integrated battery pressure relief and terminal isolation system
Granted: March 5, 2013
Patent Number:
8389139
A system for integrating the venting feature of a battery with a means for simultaneously disconnecting the cell from the battery pack, thereby isolating the cell, is provided. The provided battery interconnect system is comprised of a battery, a connector plate for electrically coupling the battery to a battery pack, and an interruptible electrical connector for electrically coupling the connector plate to a battery terminal vent. The venting region, defined by scoring on the battery…
Method of fabricating a rotor assembly for an electric motor
Granted: February 5, 2013
Patent Number:
8365392
A rotor assembly and a method for fabricating the same are provided in which a solid rotor ring is formed at either end of a stack of laminated discs, the solid rotor rings yielding improved electrical and mechanical characteristics in a low weight assembly. The solid rotor rings are fabricated by brazing slugs between the end portions of the rotor bars, the braze joints contacting a large percentage (at least 90 %) of the rotor bar end portions.
Battery pack enclosure with controlled thermal runaway release system
Granted: February 5, 2013
Patent Number:
8367233
A battery pack thermal management system is provided that is comprised of at least one enclosure failure port integrated into at least one wall of a battery pack enclosure, where the enclosure failure port(s) remains closed during normal operation of the battery pack, and opens during a battery pack thermal runaway event, thereby providing a flow path for hot gas generated during the thermal runaway event to be exhausted out of the battery pack enclosure in a controlled fashion.
Cell separator for minimizing thermal runaway propagation within a battery pack
Granted: February 5, 2013
Patent Number:
8367239
A spacer assembly for use with a cell mounting bracket in a battery pack is provided. The spacer assembly, comprised of one or more spacers, maintains the positions of the batteries within the battery pack during a thermal event and after the cell mounting bracket loses structural integrity due to the increased temperature associated with the thermal event. By keeping the battery undergoing thermal runaway in its predetermined location within the battery pack, the minimum spacing between…
Battery pack enclosure with controlled thermal runaway release system
Granted: January 29, 2013
Patent Number:
8361642
A battery pack thermal management system is provided that is comprised of at least one enclosure failure port integrated into at least one wall of a battery pack enclosure, where the enclosure failure port(s) remains closed during normal operation of the battery pack, and opens during a battery pack thermal runaway event, thereby providing a flow path for hot gas generated during the thermal runaway event to be exhausted out of the battery pack enclosure in a controlled fashion.
Method and apparatus for maintaining cell wall integrity using a high yield strength outer casing
Granted: January 29, 2013
Patent Number:
8361649
A method and apparatus is provided in which a pre-formed secondary can comprised of one or more layers of a high yield strength material is positioned around the pre-formed battery case, the pre-formed secondary can inhibiting the flow of hot, pressurized gas from within the battery through perforations formed in the battery casing during a thermal runaway event.
Compact energy absorbing vehicle crash structure
Granted: January 15, 2013
Patent Number:
8353545
A crash structure is provided that is interposed between a vehicle's bumper and a vehicle side rail, the crash structure providing relatively level loading in a compact structure that is easily removed and replaced during post-collision repairs. The structure includes an actuator member coupled to the bumper, the actuator member passing into, and slidably disposed within, a hollow housing of the crash structure. The hollow housing contains a plurality of deformable members that at least…
Vehicle seat mount
Granted: January 1, 2013
Patent Number:
D673393
Operation of a range extended electric vehicle
Granted: January 1, 2013
Patent Number:
8346419
One embodiment includes a method that includes monitoring a battery state of charge circuit that is coupled to a vehicle battery, calculating an averaged value of the state of charge over a time period, charging the vehicle battery by powering a generator with a fuel burning engine that powered on and powered off according to one of a first operational mode and a second operational mode, wherein in the first operational mode the engine is powered on when the battery state of charge drops…
Thermal management system with dual mode coolant loops
Granted: December 25, 2012
Patent Number:
8336319
A dual mode, thermal management system for use in a vehicle is provided. At a minimum, the system includes a first coolant loop in thermal communication with a battery system, a second coolant loop in thermal communication with at least one drive train component (e.g., electric motor, power electronics, inverter), and a dual mode valve system that provides means for selecting between a first mode where the two coolant loops operate in parallel, and a second mode where the two coolant…
Augmented vehicle seat mount
Granted: December 25, 2012
Patent Number:
8336658
A vehicle seat mounting assembly is provided in which the seat mounts are attached to body cross-members that are, in turn, mechanically coupled to battery pack cross-members contained within a battery pack enclosure mounted under the vehicle.
Vehicle integrated display and mount
Granted: December 11, 2012
Patent Number:
D672307
Selective cure of adhesive in modular assemblies
Granted: December 4, 2012
Patent Number:
8322393
The system includes a module fixture supporting a plurality of elements, the module fixture defining a plurality of bonding wells with each bonding well accepting a first portion of one or more of the elements with the module fixture including one or more apertures communicated with one or more of the bonding wells with the bonding wells having a nominal depth; and a dispensing system, coupled to the module fixture, for dispensing a high-wettability adhesive into each the bonding well…
Trickle charger for high-energy storage systems
Granted: December 4, 2012
Patent Number:
8324863
A voltage converter for charging an energy storage module from an alternating current line voltage, includes a first charging stage, coupled to the energy storage module, converting the line voltage to a first rectified direct current module charging voltage communicated to the energy storage module, the first rectified direct current module charging voltage greater than the line voltage, the first charging stage including an inductance for communicating a first charging current to the…
Method for detecting battery thermal events via battery pack pressure monitoring
Granted: November 20, 2012
Patent Number:
8313850
A method for detecting and responding to a battery thermal event within a sealed battery pack is provided. The method includes the steps of monitoring and characterizing the pressure within the battery pack over time, where identifying a battery thermal event is based on the pressure data fitting a specific curve shape, and performing a preset response when a battery thermal event is identified. The method may additionally monitor for a secondary effect associated with the battery…
Method and apparatus for maintaining cell wall integrity using a high yield strength outer sleeve
Granted: November 6, 2012
Patent Number:
8304108
A method and apparatus is provided in which a pre-formed sleeve or pre-formed secondary can comprised of one or more layers of a high yield strength material is positioned around the pre-formed battery case, the pre-formed sleeve/secondary can inhibiting the flow of hot, pressurized gas from within the battery through perforations formed in the battery casing during a thermal runaway event.
Collection, storage and use of metal-air battery pack effluent
Granted: October 30, 2012
Patent Number:
8298692
A system and method for collecting, storing and using the oxygen-rich effluent generated when charging a metal-air battery pack is provided.
Apparatus for the external application of battery pack encapsulant
Granted: October 23, 2012
Patent Number:
8293393
An apparatus for simplifying battery pack encapsulation is provided. The battery pack includes a pair of complementary housing members with each housing member including a plurality of cell constraints into which the ends of corresponding battery cells are inserted during assembly. One or both housing members also include at least one, and preferably a plurality, of raised encapsulant injection ports. The raised encapsulant injection ports are designed to extend above the surface of the…
Vehicle wheel front face
Granted: October 16, 2012
Patent Number:
D669008
