Delphi Technologies, Inc.

Enerdel, Inc.

Duane D Kruger

Robert C Beer

Georgette N Young

Thomas Hubert Van Steenkiste

Stephen W Moore

Robert Thomas Wendling

Brad T Hanauer

Richard E Teets

A framed lithium battery cell group includes a first frame member () and a second frame member (). The frame members are locked together, clamping the lithium battery cell pack () on the seal edge surfaces (), thereby providing structural rigidity and protection from damage due to handling and vibration. Each of the frame members () has multiple pins () and sockets () on the side opposite the clamping surface () to facilitate aligning and stacking multiple lithium battery cell pack and frame assemblies to form a lithium battery cell group (). Each of the frame members () include a buss bar capture feature () having a bus bar () inserted therein for electrically connecting all of the terminals for a given lithium battery pack group to the buss bar ().

Apparatus and method for securing battery cell packs

A system for operating a hybrid vehicle that includes a chargeable energy storage device, a single dynamo (motor/generator combination) an internal combustion engine, and a torque coupling device configured to variably couple the engine to the dynamo. The torque coupling device is such that using only a single dynamo, the system is able to operate in different modes expected of hybrid vehicles, such as: electric drive only, engine drive only, electric and engine drive combined, and charging of the chargeable energy storage device.

Hybrid vehicle system and controller

A battery safety system that includes a battery terminal configured for making an electrical connection to the system, an electrical disconnect operable to a disconnected state whereby a battery voltage is electrically isolated from the battery terminal, and a connected state, whereby the battery voltage is electrically coupled to the battery terminal. The battery safety system also includes and a terminal guard movable to an exposed position effective to allow making the electrical connection to the battery terminal, and a protected position effective to prevent electrical contact with the battery terminal other than via the electrical connection. The system is configured to prevent the electrical disconnect from being operated to the connected state if the terminal guard is not at the protected position. The system provides a double action safety interlock that makes the action of connecting and disconnecting battery voltage to and from battery terminals or battery cables separate from the action of covering and uncovering the battery terminals, and so reduces the risk of electrical shock when the battery is being manufactured, installed, serviced, or otherwise handled.

Battery safety system

A prismatic-cell battery pack is provided with integral coolant passages including an intake plenum, an exhaust plenum, and a distributed array of coolant channels coupled between the intake plenum and the exhaust plenum. Coolant medium forced into the intake plenum enters the coolant channels in parallel, draws heat away from the battery cells, and then enters the exhaust plenum for expulsion into the atmosphere. The battery pack is configured as a set of stackable interlocking battery cell modules including at least one battery cell in thermal proximity to an array of coolant channels distributed over the profile of the battery cell, and a pair of peripheral chambers joined to opposite ends of the coolant channels to form the intake and exhaust plenums when the modules are arranged and interlocked in a lineal stack.

Prismatic-cell battery pack with integral coolant passages

A process for physically bonding two parts to each other is disclosed. In addition, a process for forming electrical connections have a low resistance is disclosed. The process is generally applicable to the joining of two parts each formed from a metal, an alloy, or a combination thereof. The process finds special use in the formation of multi-celled batteries. The process involves placing two parts or electrical conductors in contact with each other and then bonding them to each other using a kinetic spray process and powder particles. In formation of a multi-celled battery the particles are preferably electrically conductive. The process enables for rapid and cost effective formation of a physical connection. In addition, the connection can have an electrical resistance of less than about 0.5 milli Ohms and strength equal or greater than ultrasonic welding. The process has the advantage of being a low temperature process thereby lowering the risk of thermal damage to the parts or cells of a multi-cell battery during formation of the connection.

Secure physical connections formed by a kinetic spray process

A pressure connection apparatus includes a conductive spring member having first and second end portions that are curved, and first and second retaining members having curved pockets that are oppositely oriented for receiving the first and second curved ends of the conductive spring member. An aluminum foil terminal of one battery is sandwiched between the conductive spring and the pocket of the first retaining member, while a copper foil terminal of another battery is sandwiched between the conductive spring and the pocket of the second retaining member. The spring member is clad with aluminum on one side and copper on the other, and the end portions are oppositely curved so that the aluminum-clad side contacts the aluminum foil terminal within the pocket of the first retaining member, and the copper-clad side contacts the copper foil terminal within the pocket of the second retaining member.

Terminal connection apparatus for battery cells having foil terminals

True Top Dead Center (TDC) of an engine piston is determined through determination of the Location of Peak Pressure (LPP) using either of two simplified algorithms. A Heat Loss Offset (HLO), drawn from a look-up table based on engine speed, molar mass of the air being compressed, and heat loss rate to the cylinder walls, is added to the calculated LPP to provide a corrected and true TDC position for each piston, which corrects for errors in target wheel tooth location of a camshaft position sensor and for any misalignment in the target wheel during installation on an engine. Preferably, such a calculation is carried out for each cylinder of a multi-cylinder engine during operation thereof, thus further correcting for machining errors in the crankshaft and for crankshaft bending during the life of the engine. The invention thus allows for more accurate combustion calculations for each individual cylinder.

Method and apparatus for determining TDC for each cylinder of a multi-cylinder internal combustion engine

A battery assembly is designed to include a plurality of cells positioned parallel to each other. A frame including end supports position the cells appropriately. Each of the cells includes a first terminal and a second terminal. Two buses are positioned over all of the first terminals and all of the second terminals. Each of the buses includes slots allowing the terminals to extend therethrough. Once through, the terminals are bent over the bus bar. A slide is then positioned over the terminals protecting the terminals and maintaining the terminals in electrical contact with each other. This battery assembly allows more than three cells to be connected to each other and is versatile enough to allow the removal of certain cells to enhance the airflow through the battery assembly.

Battery assembly and method of making same

A vehicle having an electric hybrid power system is provided. A battery pack stores electricity to power the electric motor. The battery pack includes a first plurality of batteries connected in parallel with a second plurality of batteries. The first plurality of batteries are Nickel Metal Hydride (NiMH), and the second plurality of batteries provide high power output at lower temperatures. In addition, the second plurality of batteries may also have a low energy density.

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Westfield, IN, United States of America

Duane D Kruger