Hazard mitigation within a battery pack using metal-air cells
Granted: November 5, 2013
Patent Number:
8574732
A system and method for mitigating the effects of a thermal event within a battery pack is provided in which the hot gas and material generated during the thermal runaway of at least one non-metal-air cell of a plurality of non-metal-air cells is directed through one or more metal-air cells, the metal-air cells absorbing at least a portion of the thermal energy generated during the event before it is released to the ambient environment. As a result, the risks to vehicle passengers,…
Front rail reinforcement system
Granted: November 5, 2013
Patent Number:
8573683
A front structure for a vehicle is provided, the structure including (i) a pair of front rails (i.e., front left hand rail and front right hand rail) spaced apart in a widthwise direction with each rail extending lengthwise, where one end portion of each rail is mechanically coupled to the vehicle's bumper and the other end portion of each rail is mechanically coupled to a torque box, and where each rail is comprised of a polygonal-shaped upper hollow channel and a polygonal-shaped lower…
Method for making an efficient rotor for an electric motor
Granted: November 5, 2013
Patent Number:
8572837
A method of making a rotor assembly for an electric motor by adding bars made out of a conducting material such as copper, to spaces between the teeth of a stack of discs, inserting bars referred to as “slugs”, also made out of a conducting material such as copper, in the spaces between the bars on either side of the stack of discs, radially compressing the bars and discs, one or both of which are plated or otherwise coated with a braising material, and then heating the rotor to…
Dual load path design for a vehicle
Granted: October 29, 2013
Patent Number:
8567849
A system for absorbing and distributing front impact forces in a vehicle is provided, the system including a primary impact system and a secondary impact system, each of which includes a bumper and a structure for transferring impact loads. The primary impact system includes a primary bumper and a pair of front rails spaced apart in a widthwise direction with each rail extending lengthwise, where one end portion of each rail is mechanically coupled to the vehicle's bumper and the other…
Swept front torque box
Granted: October 29, 2013
Patent Number:
8567856
A front structure for a vehicle is provided, the structure including (i) a pair of front rails spaced apart in a widthwise direction with each rail extending lengthwise, and where each rail is comprised of a polygonal-shaped upper hollow channel and a polygonal-shaped lower hollow channel with the upper and lower channels sharing a common wall; and (ii) a pair of curvilinear torque boxes, where one curvilinear torque box is mechanically attached to the upper and lower polygonal-shaped…
Bumper mounting plate for double channel front rails
Granted: October 29, 2013
Patent Number:
8567855
A front structure for a vehicle is provided, the structure including (i) a pair of front rails (i.e., front left hand rail and front right hand rail) spaced apart in a widthwise direction with each rail extending lengthwise, and where each rail is comprised of a polygonal-shaped upper hollow channel and a polygonal-shaped lower hollow channel with the upper and lower channels sharing a common wall; and (ii) a pair of bumper mounting plates, where one bumper mounting plate is interposed…
Method for optimizing battery pack temperature
Granted: October 15, 2013
Patent Number:
8555659
A method for limiting the adverse effects of temperature on the electrical energy storage system (ESS) of an electric vehicle after the vehicle has been turned off is provided. In general, whether or not coolant is circulated through a coolant loop coupled to the ESS depends on the difference between the ambient temperature and a preset temperature, the preset temperature typically corresponding to the temperature of the ESS.
Control, collection and use of metal-air battery pack effluent
Granted: October 15, 2013
Patent Number:
8557414
A system and method for maintaining an ambient oxygen concentration below a preset concentration while charging a metal-air battery pack is provided, the system utilizing an on-board means for collecting and storing the oxygen-rich effluent generated during the charge cycle.
Battery pack venting system
Granted: October 15, 2013
Patent Number:
8557415
A thermal management system is provided that minimizes the effects of thermal runaway within a battery pack. The system is comprised of a sealed battery pack enclosure configured to hold a plurality of batteries, where the battery pack enclosure is divided into a plurality of sealed battery pack compartments. The system also includes a plurality of battery venting assemblies, where at least one battery venting assembly is integrated into each of the sealed battery pack compartments, and…
Battery pack directed venting system
Granted: October 15, 2013
Patent Number:
8557416
A thermal management system is provided that minimizes the effects of thermal runaway within a battery pack, the system using an integrated battery venting assembly comprised of an integrated exhaust port, a valve retention plate that covers the exhaust port and includes a plurality of retention plate ports, and a plurality of valves that are configured to seal the retention plate ports under normal conditions and unseal the retention plate ports during thermal runaway. As hot gas passes…
Low temperature charging of Li-ion cells
Granted: October 8, 2013
Patent Number:
8552693
A battery cell charging system, including a charger and a controller, for low-temperature (below about zero degrees Celsius) charging a lithium ion battery cell, the battery cell charging system includes: 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 having: a non-low-temperature charging stage for charging the battery cell using a…
Thermal barrier structure for containing thermal runaway propagation within a battery pack
Granted: September 24, 2013
Patent Number:
8541126
A battery pack is provided that includes one or more thermal barrier elements, the thermal barrier elements dividing the cells within the battery pack into groups of cells. The thermal barrier elements that separate the cells into groups prevent a thermal runaway event initiated in one group of cells from propagating to the cells within a neighboring group of cells.
Overmolded thermal interface for use with a battery cooling system
Granted: September 24, 2013
Patent Number:
8541127
A cooling manifold assembly for use in a battery pack thermal management system is provided. The cooling manifold assembly includes a coolant tube that is interposed between at least a first row of cells and a second row of cells, where the first and second rows of cells are adjacent and preferably offset from one another. A thermal interface layer is overmolded onto the cooling tube, the thermal interface layer including a plurality of pliable fingers that extend away from the cooling…
Efficient dual source battery pack system for an electric vehicle
Granted: September 24, 2013
Patent Number:
8543270
A method of optimizing the operation of the power source of an electric vehicle is provided, where the power source is comprised of a first battery pack (e.g., a non-metal-air battery pack) and a second battery pack (e.g., a metal-air battery pack). The power source is optimized to minimize use of the least efficient battery pack (e.g., the second battery pack) while ensuring that the electric vehicle has sufficient power to traverse the expected travel distance before the next battery…
Vehicle port door with wirelessly actuated unlatching assembly
Granted: September 24, 2013
Patent Number:
8539990
A port door unlatching system is provided that may be used to open the door covering the charge port of an electric vehicle, or the door covering the fuel filler port of a conventional vehicle. The system includes a fuel delivery subsystem with a fuel coupler (e.g., a charging connector or a gas nozzle) designed to transfer fuel from the source to the vehicle via the vehicle's fuel port. The fuel coupler includes a switch that when toggled, causes a control signal to be wirelessly…
State of charge range
Granted: September 17, 2013
Patent Number:
8536825
A system and method for improving cycle lifetimes for a lithium-ion battery pack, particularly for adapting to a dynamic use profile for a user. A battery cell pack charging system, including a charger and a controller, for charging a lithium-ion battery cell pack, the battery cell pack charging system has a circuit for charging the battery cell pack using an adjustable charging system including an adjustable charge profile to charge the battery cell pack wherein the adjustable charge…
Dynamic antiwhiplash apparatus and method
Granted: September 17, 2013
Patent Number:
8534703
A passenger seat protection system for a seated passenger of a vehicle includes a seat back supporting a pressurizable vessel storing a quantity of pressurized gas within a compartment, the compartment defined by one or more walls that collapse responsive to a force applied to the seat back by the seated passenger in a rear impact of the vehicle; a headrest including a bladder responsive to a gas pressure from the quantity of pressurized gas to transition an expansion of the headrest…
Dual hinged vehicle door
Granted: August 20, 2013
Patent Number:
8511738
A dual hinged door assembly for a vehicle is provided, the assembly including an upper door portion and a lower door portion. The upper door portion, which may include a window, pivots about a primary axis formed by its juncture with a structural member in the roof. The lower door portion, which may include a window, pivots about a secondary axis formed by its juncture with the upper door portion. Primary and secondary drive systems may be used to provide independent powered motion of…
Integrated energy absorbing vehicle crash structure
Granted: August 20, 2013
Patent Number:
8511745
A crash structure is provided that is integrated within a vehicle side rail, the crash structure providing relatively level loading during a collision. 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 partially surround a first portion of the actuator member. A second portion of the actuator…
Control system for use with a dual hinged vehicle door
Granted: August 20, 2013
Patent Number:
8511739
A control system for use with a vehicle's dual hinged door assembly is provided, the control system including a door switch, upper and lower door portions, primary and secondary door drive systems and a controller. The upper door portion pivots about a primary axis formed by its juncture with a structural member in the roof while the lower door portion pivots about a secondary axis formed by its juncture with the upper door portion. Primary and secondary drive systems provide independent…
