Gm Global Technolgoy Operations, Inc.

John A Martuscelli

Alexander M Bilinski

Jeffrey A Bozeman

Randall S Champagne

Jared Phillips

Anahita Rastkar

Michael E Fraeyman

Presented are battery assemblies with integrated fuel tanks, methods for making/using such battery assemblies, and fuel cell electric vehicles having rechargeable traction battery packs with integrated fiber-composite hydrogen fuel tanks. A rechargeable energy storage system (RESS) assembly includes a battery pack housing with an internal battery module compartment located between two tank mounting cavities. Each mounting cavity is recessed into a respective lateral side of the battery pack housing. Multiple rechargeable battery modules are electrically interconnected with one another and mounted inside the battery module compartment. Each battery module contains multiple battery cells, such as a stack of series-connected lithium-ion pouch cells. A fuel tank is mounted in each of the tank mounting cavities on the lateral sides of the battery pack housing. Each fuel tank, which may be fabricated from a carbon fiber reinforced polymer, stores and selectively dispenses a fuel, such as a hydrogen-rich, compressed gas fuel.

Propulsion battery packs with integrated fuel tank mounting systems

Presented are fuel cell systems and control logic for extracting water from system exhaust, methods for making/using such systems, and electric-drive vehicles with aftertreatment systems for extracting water from fuel cell exhaust. An aftertreatment system for a fuel cell stack includes a condensate generator that fluidly connects to the fuel cell stack to receive exhaust output therefrom. The condensate generator includes an evaporator core with a refrigerant line that actively cool the exhaust via controlled circulation of refrigerant fluid. A condensate collector fluidly connected to the condensate generator includes a reservoir housing with a condensate trap that separates entrained water vapor from the cooled exhaust. The reservoir housing collects the separated water vapor as liquid water. A liquid storage container fluidly connected to the condensate collector receives and stores the collected water. An expansion valve regulates the amount of refrigerant fluid passed into the evaporator core through the refrigerant line.

Fuel cell architectures, aftertreatment systems, and control logic for exhaust water extraction

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Shelby Township, MI, United States of America

John A Martuscelli