Gentherm Gmbh

A123 Systems LLC

Michael Peter Ciaccio

Brian Moorhead

Timothy Hughes

Michael Weiss

A function module for electrical applications and method of making a function module for electrical applications. The function module includes: a functional member having a piercing area with at least one aluminum conductor trace; and an electrical connector having at least one piercing member. The at least one piercing member is configured to pierce through the at least one aluminum conductor trace in an electrically conductive manner and provide a form-fit connection between the functional member and the electrical connector within the piercing area. The functional member and the electrical connector are joined together within the piercing area by means of a solder connection.

Function module for electrical applications

A system for discharging or charging a capacitor of a hybrid vehicle according to the present disclosure includes a target state of charge (SOC) module and a capacitor charge/discharge module. The target SOC module determines a target state of charge of the capacitor based on a speed of the vehicle. The capacitor charge/discharge module determines whether a state of charge of a capacitor is greater than a target state of charge. The capacitor charge/discharge module dissipates power from the capacitor to at least one of a battery of the vehicle and an electrical load of the vehicle when the state of charge of the capacitor is greater than the target state of charge.

Systems and methods for supplying power in a hybrid vehicle using capacitors, a battery and one or more DC/DC converters

A battery and capacitor assembly for a hybrid vehicle includes a plurality of battery cells, a plurality of capacitor cells, a cooling plate, a pair of end brackets, and a housing. The plurality of capacitor cells are arranged adjacent to the plurality of battery cells such that the plurality of battery cells and the plurality of capacitor cells form a cell stack. The pair of end brackets are disposed at opposite ends of the cell stack and are attached to the cooling plate. The pair of end brackets compress the plurality of battery cells and the plurality of capacitor cells. The housing is attached to the cooling plate and encloses the cell stack and the pair of end brackets.

Battery and capacitor assembly for a vehicle and a method for heating and cooling the battery and capacitor assembly

A method for manufacturing a double-sided, single conductor laminate includes providing a laminated substrate that includes a conductive layer, an adhesive layer and a support layer; dry milling a trace pattern in the laminated substrate by removing selected areas of the conductive layer and the adhesive layer; and attaching a first cover layer using a first adhesive layer to the conductive layer. The first cover layer includes one or more precut access holes that align with one or more traces of the trace pattern.

Method of manufacturing a double-sided laminate including dry milling a conductive trace pattern and providing a cover layer with precut access holes that expose the trace pattern

A power management system for a vehicle includes a first battery monitoring module configured to monitor a first state of charge (SOC) of a first battery of the vehicle. The first battery has a first nominal voltage. A second battery monitoring module is configured to monitor a second SOC of a second battery of the vehicle. The second battery has a second nominal voltage that is greater than the first nominal voltage. A control module is configured to selectively apply power to a heater of the second battery based on an estimated value of the second SOC of the second battery at a next startup of an engine.

Dual voltage battery system for a vehicle

A method of manufacturing a flexible circuit comprises providing a laminated substrate that includes a conductive layer, an adhesive layer, and a support layer. The method comprises forming conductive traces by removing selected portions of the conductive layer and the adhesive layer by dry milling the laminated substrate. The method comprises applying a protective coating to the conductive traces. The method comprises dispensing a solder material on the protective coating at a first connection point and arranging a first component at the first connection point. The method comprises heating the solder material to remove the protective coating from the first connection point and to connect the first component to one of the conductive traces at the first connection point. The method comprises attaching a second component to the conductive layer at a second connection point that is free of the protective coating by a process other than soldering.

Methods of manufacturing flex circuits with mechanically formed conductive traces

A power management system for a vehicle includes a first battery monitoring module configured to monitor a first state of charge (SOC) of a first battery of the vehicle. The first battery has a first nominal voltage. A second battery monitoring module is configured to monitor a second SOC of a second battery of the vehicle. The second battery has a second nominal voltage that is greater than the first nominal voltage. A control module is configured to, using a direct current (DC) to DC converter, selectively charge the second battery with power from the first battery until the second SOC of the second battery is greater than or equal to a predetermined SOC.

In one example, the present disclosure describes a battery and capacitor assembly for a hybrid vehicle that includes a plurality of battery cells, a plurality of capacitor cells, a cooling plate, a pair of end brackets, and a housing. The plurality of capacitor cells are arranged adjacent to the plurality of battery cells such that the plurality of battery cells and the plurality of capacitor cells form a cell stack. The pair of end brackets are disposed at opposite ends of the cell stack and are attached to the cooling plate. The pair of end brackets compress the plurality of battery cells and the plurality of capacitor cells. The housing is attached to the cooling plate and encloses the cell stack and the pair of end brackets.

A power management system for a hybrid vehicle including an engine includes a vehicle power bus distributing power from a battery to vehicle loads. A capacitor includes one of a plurality of supercapacitors and a plurality of ultracapacitors. A starter/generator controller communicates with the capacitor and the battery. A power management module is configured to supply current from the capacitor to the starter/generator controller during cranking of the engine; and supply current from the battery to the starter/generator controller during the cranking of the engine. The power supplied by the battery is greater than or equal to 2% and less than or equal to 20% of a total power supplied to the starter/generator controller during the cranking of the engine.

Double-sided, single conductor laminated substrate

A battery pack for supplying energy to propel a vehicle is disclosed. In one example, a battery pack includes a thermoplastic over mold for providing resistance to liquid is disclosed. The battery pack may have increased resistance to battery pack degradation.

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Chelsea, MI, United States of America

Michael Peter Ciaccio