Gm Global Technolgoy Operations, Inc.

Marc Becker

Peter Kilian

Peter Willimowski

Volker Formanski

Remy Fontaine

Thomas Herbig

Steven D Burch

Sebastian Lienkamp

Abdullah Basar Alp

Oliver Maier

Thomas W Tighe

Uwe Hannesen

Christian Koenig

Erik Schumacher

A thermal management system that provides air cooling and heating for a battery by flow-shifting air through a battery enclosure. The battery includes a plurality of battery cells provided in the enclosure. The enclosure includes a first manifold having a first end and second end and second manifold opposite to the first manifold having a first end and second end. The thermal management system includes a plurality of valves for allowing air flow into and out of the first end or the second end of the first manifold and a second valve for allowing air flow into and out of the first end or the second end of the second manifold to provide the flow-shifting.

Method for air cooling of an electric vehicle traction battery with flow shifting

A system and method for identifying leaks in a cathode sub-system of a fuel cell system. An air flow meter is provided up-stream of a compressor and monitors the air flowing into the compressor. When an air leakage diagnostic is commanded, a fuel cell stack by-pass valve and back-pressure valve are closed so that no air flows through or around the stack, and the recirculation valve is opened so that the air flows around the compressor. By knowing the leakage through the by-pass valve and the back-pressure valve, any flow above those values measured by the air flow meter gives an indication of air leakage out of the cathode sub-system components.

Method for a fuel cell air system leakage diagnostic

A fuel cell system is disclosed that employs an expander for recovering mechanical energy from a cathode exhaust fluid produced by the fuel cell system to generate torque. The expander is coupled to a shaft of a compressor with a freewheel mechanism, wherein the freewheel mechanism transfers the torque from the expander to the compressor when a rate of rotation of a driveshaft of the expander is greater than the rate of rotation of the shaft of the compressor, and selectively militates against the expander acting as a restrictor to the shaft of the compressor when a rate of rotation of the driveshaft of the expander is substantially equal to or less than a rate of rotation of the shaft of the compressor.

Compressor system with a freewheeling expander

A fuel cell assembly having a flow distribution subassembly that comprises four sets of flow channels, the first set facing an anode for distribution of a fuel reactant to said anode, the second set facing a cathode for distribution of an oxidant to said cathode, the third set in flow communication with said second set and in heat transfer relation with at least one of said anode and said cathode, and the fourth set receiving a coolant different from said oxidant.

Fuel cell design with an integrated heat exchanger and gas humidification unit

A technique for determining the relative humidity of the cathode input airflow to a fuel cell stack that eliminates the need for a dew-point sensor. The cathode input airflow is humidified by a water vapor transfer unit that uses water in the cathode exhaust gas. The technique employs an algorithm that determines the flow of water into the cathode inlet of the stack. In one embodiment, the algorithm determines the volume flow of water through the water vapor transfer unit using the Arrhenius equation, and then converts the water volume flow to a water mole flow. The algorithm then uses the water mole flow through the water vapor transfer unit and the water mole flow of ambient air to determine the water mole flow into the cathode inlet. The algorithm then uses the water mole flow into the cathode inlet to determine the relative humidity of the cathode airflow.

Sensorless relative humidity control in a fuel cell application

A method and system for controlling temperature in an electric vehicle battery pack such that battery pack longevity is preserved, while vehicle driving range is maximized. A controller prescribes a maximum allowable temperature in the battery pack as a function of state of charge, reflecting evidence that lithium-ion battery pack temperatures can be allowed to increase as state of charge decreases, without having a detrimental effect on battery pack life. During vehicle driving, battery pack temperature is allowed to increase with decreasing state of charge, and a cooling system is only used as necessary to maintain temperature beneath the increasing maximum level. The decreased usage of the cooling system reduces energy consumption and increases vehicle driving range. During charging operations, the cooling system must remove enough heat from the battery pack to maintain temperatures below a decreasing maximum, but this has no impact on driving range.

Method for optimized design and operation of battery cooling system in electric vehicles

A system for cooling a fuel cell stack and a drive unit in a fuel cell vehicle is disclosed, wherein the system includes a drive unit and a fuel cell stack. An oil cooling loop for the drive unit includes a three way valve, a liquid to liquid heat exchanger, and a pump. The liquid to liquid heat exchanger may be used to transfer drive unit off heat into the stack coolant loop. By not using an oil to air heat exchanger overall heat exchanger arrangement air side pressure drop can be minimized and airflow increased. The three way valve allows decoupling of the cooling loops if needed to inhibit negative impact on the fuel cell stack.

Apparatus for optimized cooling of a drive unit and a fuel cell in a fuel cell vehicle

A fuel cell system that employs a heat exchanger and a charge air cooler for reducing the temperature of the cathode inlet air to a fuel cell stack during certain system operating conditions so that the cathode inlet air is able to absorb more moisture in a water vapor transfer unit. The system can include a valve that selectively by-passes the heat exchanger if the cathode inlet air does not need to be cooled to meet the inlet humidity requirements. Alternately, the charge air cooler can be cooled by an ambient airflow.

Water transfer efficiency improvement in a membrane humidifier by reducing dry air inlet temperature

A method for quickly and efficiently heating a fuel cell stack at system start-up. The method uses and prioritizes various stack heat sources based on their efficiency to heat the stack. A thermal set-point for heating the stack to the desired temperature is determined based on the ambient temperature and, the stack cooling fluid temperature. The set-point is then compared-to the stack heating provided by the heat sources that are operating through normal system start-up operation. If more heat is necessary to reach the set-point, the method may first charge a system battery using stack power where the load causes the fuel cell stack to heat up. If additional heating is still required, the method may then turn on a cooling fluid heater, then flow a small amount of hydrogen into the cathode inlet stream to provide combustion, and then increase the compressor load as needed.

Fuel cell system warm-up strategy with reduced efficiency losses

A multi-stage compressor system that compresses air supplied to a cathode of a fuel cell system includes a first stage compressor that compresses inlet air to provide a first pressurized air stream at a first pressure. A second stage compressor includes a compression unit that compresses the first pressurized air stream to a second pressurized air stream at a second pressure. A drive unit drives the compression unit using expansion energy of an exhaust stream of the fuel cell. A first heat exchanger enables heat transfer between the second pressurized air stream and the exhaust stream to heat the exhaust stream.

Growing community of inventors

Idstein, Germany

Marc Becker