Gm Global Technolgoy Operations, Inc.

Christopher A Schlaupitz

Robert J Heydel

Andrew J Namou

Todd F Mackintosh

John Reed

Daniel F Witting

William Lupsha

Brian A Swain

A method for assembling a battery cell includes assembling an electrode stack that includes first electrodes, second electrodes, and separators. A first conductive adhesive pad is formed on an end cap, wherein the first conductive adhesive pad electrically couples to a first terminal arranged on the end cap. A second conductive adhesive pad is formed on an enclosure, wherein the second conductive adhesive pad electrically couples to a second terminal arranged on the enclosure. The end cap is installed onto the electrode stack with the first cell tabs engaging the first conductive adhesive pad. The electrode stack is inserted into the enclosure such that the plurality of the second cell tabs engages the second conductive adhesive pad. The end cap is assembled onto the enclosure.

Electrochemical battery module and method therefor

A tab for use in a battery comprises a metal piece that comprises a cross-sectional area geometry that is a rhombus, a parallelogram or a trapezoid when viewed in a lateral direction. The metal piece further comprises a cross-sectional area geometry having a variable thickness when viewed in a longitudinal direction that is perpendicular to the lateral direction. When viewed in the longitudinal direction, a tab thickness tat a point where the tab is in contact with an electrode is less than the tab thickness tat a point where the tab contacts a pouch.

Battery tab design, method of manufacture thereof and batteries comprising the same

A battery system for a motor vehicle or other system includes a voltage bus with positive and negative bus rails, and first and second battery packs. The battery packs are arranged between and connected to rails. High-voltage switches are collectively configured to selectively interconnect the battery packs in a series or parallel battery arrangement. The switches include a pair of mutually-exclusive three-way/two-position contactors each having a series connection position and parallel connection position corresponding to the respective series and parallel battery arrangements. An electric powertrain includes an electrical load connected to the battery system, and a controller coupled to the switches. In response to a battery mode selection signal, the controller selectively transitions the contactors from the series connection position to the parallel connection position, or vice versa. A motor vehicle includes road wheels, a body, and the electric powertrain.

Electric powertrain with multi-pack battery system and mutually-exclusive 3-way contactor

A three-state contactor for an electrical system having a battery pack and voltage bus rail includes first and second pairs of electrical terminals. The first pair of terminals is separated by a first circuit gap in a first circuit path extending between the bus rail and an electrode terminal of the battery pack. The second pair of terminals is separated by a second circuit gap in a second circuit path extending between the bus rail and electrode terminal. A contactor arm, in response to a corresponding switch activation signal, translates in an orthogonal direction with respect to its longitudinal axis between a first ON state position, an OFF position, and a second ON position to close the first circuit gap, open both circuit gaps, or close the second circuit gap, respectively. A multi-pack battery system and an electric powertrain may use the contactor.

Electric powertrain with battery system having a three-state high-voltage contactor

A battery system includes high-voltage switches, including a multi-pole contactor. Multiple packs are connectable in a series or parallel configuration via the switches. The contactor includes first and second pairs of electrical terminals separated by a respective circuit gap, with respective contactor arms simultaneously closing or opening the gaps. At all times, internal switches formed by the gaps and arms have the same ON/OFF state corresponding to the circuit gaps both being closed or both being open. Two of the contactors may be used to connect the battery packs to a DC fast-charging station, and to connect electrode terminals of the battery packs to a bus rail, respectively. An electric powertrain includes the battery system and an electrical load, including a rotary electric machine, that is connected to a power inverter and to a mechanical load.

Electric powertrain with battery system having multi-pole high-voltage contactor

A method according to the present disclosure provides a ground connection between a first component and a vehicle body rail through a coating disposed on the vehicle body rail. The method includes inserting a grounding bushing into an aperture in a second component, positioning the second component between the first component and the vehicle body rail, placing the grounding bushing in contact with the first component, and inserting a fastener through the first component, through the grounding bushing, and into the vehicle body rail. The method further includes tightening the fastener to clamp the first component and the grounding bushing between a head of the fastener and the vehicle body rail and thereby cause the grounding bushing to pierce through the coating disposed on the vehicle body rail to provide the ground connection between the first component and the vehicle body rail.

Grounding bushing and a method of using the grounding bushing to provide a ground connection between a component and a vehicle body rail

A fastener-holder apparatus is provided. The fastener-holder apparatus includes a fastening member; and a holder member movably connected to the fastening member. The fastener-holder apparatus may be attachable to a vehicle.

Adjustable fastener-holder assembly

A method and system for power management among batteries of varying states of health. Two or more battery packs are switched on and off in square wave pulses to energize a multi-winding transformer, and the output of the transformer is used to power a load. As the state of charge of the battery packs decrease at different rates, the duty cycle of each battery pack's switch pulse is made proportional to its state of charge relative to the other battery packs. The battery pack with the greatest state of charge has the longest on-time and provides the most energy to the transformer, yet all battery packs contribute. A baseline duty cycle is computed by a proportional integral control module, based on voltage measurements at the load. Energy contribution is managed so that state of charge does not diverge even when the battery packs have widely varying states of health.

Scalable method of proportional active state of charge balancing for managing variations in the state of health of batteries

Methods and systems for balancing battery states of charge in a multi-sectioned battery. In some embodiments, states of health and states of charge of one or more sections of a multi-sectioned battery may be determined. A relationship between the states of charge and states of health of the battery sections may be determined. This information may be used apply a balancing algorithm to redistribute energy between the various battery sections in order to reduce a spread between the states of charge due to the varying states of health.

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White Lake, MI, United States of America

Christopher A Schlaupitz