Gm Global Technolgoy Operations, Inc.

Herman K Phlegm

Mahmoud H Abd Elhamid

Edgar P Calderon

Timothy J Fuller

Andrew J Namou

Sami A Syed

Chih-Cheng Hsu

Milind S Gandhi

John G Dorrough

Andrew C Brenz

Andrew H Leutheuser

Craig A Kollar

Pablo Valencia, Jr

Benjamin R Christian

Robert D Drexler

Mei Cai

Taeyoung Han

Bahram Khalighi

Anne M Dailly

Kuo-Huey Chen

Roger Michael Brisbane

Kushal Narayanaswamy

Evan J Dawley

Ronald O Grover, Jr

Mark O Vann

Ronald A Lemmon

Srikanth Arisetty

Rajesh K Bhagirath

Lisa J Gross

Terrence P Wilson

A method for constant pressure regulation of battery cells includes disposing the cells in a stacked arrangement within a battery cell placement volume of an apparatus configured to maintain a constant pressure on the cells, providing a gas pressure within a chamber of the apparatus, thereby causing an initial pressure to be applied on the battery cells, and detecting an expansion of the battery cells during a predetermined timespan using a linear displacement sensor. During the predetermined timespan, if the detected expansion is less than a maximum allowable expansion minus a predetermined measurement error, then the gas pressure within the chamber is increased, and if the detected expansion is greater than the maximum allowable expansion plus the predetermined measurement error, then the gas pressure within the chamber is decreased. An apparatus for constant pressure regulation of battery cells is also provided.

Apparatus and method for constant pressure regulation of one or more battery cells

A thermal interface member configured to be disposed between a heat sink and a heat-releasing device includes a thermal interface member. The thermal interface member has a thermally conductive, cure-in-place, polymer foam pad configured to maintain uniform contact with each of the heat sink and the heat-releasing device. The thermal interface member is additionally configured to absorb the thermal energy released by the heat-releasing device and direct the released thermal energy to the heat sink. The polymer foam pad has a matrix structure including at least one of anisotropic and isotropic thermally conductive anisotropic filler material, and is characterized by foam material density below 0.5 g/cm.

Cure-in-place lightweight thermally-conductive interface

Methods and devices for providing an even distribution of waste heat in a vehicular battery pack, including a battery pack, a cold plate, a coolant reservoir, a support structure between the battery pack and the coolant reservoir, and a conformable thermal interface material for filling the space between cells of the battery pack and the coolant reservoir so as to provide thermal contact between the cells and the coolant reservoir for distributing the waste heat. In addition, methods and devices for providing an even distribution of waste heat and structural support in any heat source to heat sink for applications such as small devices such as computer motors.

Cure in place thermal interface material

A thermal interface member may comprise a substrate having a first surface and an opposite second surface, an electrically conductive layer disposed on the first surface of the substrate, and an electrically resistive layer disposed on the first surface of the substrate. The substrate may comprise a compliant electrically insulating and thermally conductive material including a polymeric matrix phase and a dispersed phase of thermally conductive particles. The conductive layer may be patterned into a first electrode and a second electrode spaced apart from the first electrode on the first surface of the substrate. The resistive layer may be in electrical contact with the first and second electrodes of the conductive layer and may comprise a resistive material having a positive resistance temperature coefficient and a resistance that increases with an increase in temperature.

Thermal interface member and method of making the same

A high voltage battery module includes a plurality of battery cells, a plurality of cooling fins dispersed between the battery cells, and a frame for holding the plurality of battery cells and the plurality of fins. An intumescent layer is proximate to at least one battery module component selected from the battery cells, the plurality of cooling fins, and the frame. The intumescent layer includes sodium silicate having formula NaSiO, pentaerythitol, a resin that is cross-linked by melamine, boron nitride particles, and triammonium phosphate.

Thermal propagation mitigation for HV battery modules

A method of leak testing a fluid passage of a part manufactured from a low conductivity material includes measuring an electrical resistance between an interior wall surface of the fluid passage of the part, and an exterior wall surface of the fluid passage of the part. The measured electrical resistance is compared to a threshold value to determine if the measured electrical resistance is equal to or greater than the threshold value, or if the measured electrical resistance is less than the threshold value. The threshold value is equal to a nominal wall thickness of the fluid passage multiplied by a resistivity of the material used to form the part. The part passes the leak test when the measured electrical resistance is equal to or greater than the threshold value. The part fails the leak test when the measured electrical resistance is less than the threshold value.

Method of leak testing a low conductivity part

A bi-fuel vehicle has an Internal Combustion Engine (ICE) to provide motive power to the vehicle by combustion of a liquid fuel and gas-phase fuel. The vehicle has a dual fuel tank including a liquid fuel tank to receive liquid fuel, contain the liquid fuel, and supply the liquid fuel for combustion in the ICE. The vehicle has a pressurizable gas-phase fuel tank defined by a wall. A gas-phase fuel is permeable through the wall. The pressurizable gas-phase fuel tank is to receive the gas-phase fuel, contain the gas-phase fuel, and supply the gas-phase fuel for combustion in the ICE. A shell envelops the pressurizable gas-phase fuel tank and defines an interior space of the liquid fuel tank. The wall is in fluid communication with the interior space. The interior space is to receive the permeated gas-phase fuel.

Bi-fuel vehicle

A battery pack with a drain plug and a circuit to detect when a liquid coolant has entered the battery pack. A soluble plug may be disposed within the cavity of the carrier; the soluble plug is configured to at least partially dissolve when fluidly coupled with a coolant allowing a portion of the coolant to flow between the inlet and the outlet and out of the battery pack. A strain gauge cooperative with the carrier such that a measured resistance change in the strain gauge corresponds to the soluble plug in contact with the liquid coolant. An associated circuit with the drain plug provides notification of the activation of the drain plug to the on-board computer systems.

Deflection sensitive coolant activated drain plug detection system for high voltage battery packs

A coated electronic device that is fire resistant includes an electronic component and an intumescent layer disposed over the electronic component. The intumescent layer includes sodium silicate having formula NaSiO, pentaerythitol, a resin that is cross-linked by melamine, boron nitride particles, and triammonium phosphate.

Thermal protection system for powered circuit boards including fuses

Systems and methods for monitoring a state of a battery system based on information related to a measured pressure within the battery system are presented. In certain embodiments, the disclosed systems and methods may utilize a pressure-sensitive smart foam material in connection with measuring a pressure within the battery system. Based on the measured pressure information, a variety of information relating to the battery system may be determined. For example, information relating to a state of a battery system, certain events occurring within the battery system, and/or battery lifecycle information may be determined based on the measured pressure information.

Systems and methods for determining battery state information based on internal battery pressure

A battery assembly includes a plurality of stacked battery cartridges. Each battery cartridge includes a first receptacle unit, a battery cell stack, and a second receptacle unit positioned within first receptacle unit. The battery cell stack includes a first battery cell, a second battery cell, and a foam layer interposed between the first battery cell and the second battery cell. The battery cell stack is positioned within the first receptacle unit, with the second receptacle unit compressing the battery cell stack. The battery module assembly also includes a receiving assembly that holds the plurality of battery cartridges.

Stackable cartridge module design

A battery pack with a drain plug and a circuit to detect when a liquid coolant has entered the battery pack. The drain plug includes a carrier defining a cavity internal to the carrier, an inlet disposed on a first surface of the carrier and an outlet disposed on a second surface of the carrier where the first surface and the second surface fluidly displaced from one another and coupled to the cavity. A soluble plug may be disposed within the cavity of the carrier; the soluble plug is configured to at least partially dissolve when fluidly coupled with a coolant allowing a portion of the coolant to flow between the inlet and the outlet and out of the battery pack. A strain gauge cooperative with the carrier such that a measured resistance change in the strain gauge corresponds to the soluble plug in contact with the liquid coolant. An associated circuit with the drain plug provides notification of the activation of the drain plug to the on-board computer systems.

A method of assembling a battery module assembly includes a step of preparing a plurality of battery cell stacks. Each battery cell stack is constructed by positioning a pre-compressed foam unit interposed between a first battery cell and a second battery cell. Each battery cell stack is positioned in a receiving frame. After such positioning, the pre-compressed foam unit of each battery cell stack is expanded.

Utilizing vacuum to pre-compress foam to enable cell insertion during HV battery module assembly

A battery module is described. The battery module includes the battery module includes a plurality of repeating frames; a plurality of battery cells positioned between the plurality of repeating frames, the battery cells having a flexible heat conducting covering, an edge of the heat conducting covering folded over an outside edge of the repeating frame; and a heat sink contacting the edge of the heat conducting covering folded over the edge of the repeating frame. A method of cooling a battery module is also described.

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Oak Park, MI, United States of America

Herman K Phlegm