Gm Global Technolgoy Operations, Inc.

Akasol Gmbh

Akasol Ag

Stephen W Raiser

Sebastian Lienkamp

George R Woody

Benno Andreas-Schott

Peter Kilian

Keming Chen

Ralf Lerch

Bernd Peter Elgas

Joachim Lauk

Kai Rittner

Mark William Verbrugge

Christopher Paul Henze

John T Hall

Alastair Gordon Anderson

Thomas P O'Meara

Remy Fontaine

Stephen J Hulsey

Richard Michael Breese

Stanley K Fujii

Thomas Vogel

Hartmut Hinz

Felix Von Borck

Björn Eberleh

Bjoern Eberleh

The present invention relates to a battery module consisting of battery cells and a cooling module comprising multiple tiers, the cooling module being designed to hold the battery cells, such as lithium-ion batteries. The cooling module consists of at least one first and one second side part, each side part having at least one flow channel, and of multiple substantially flat elements which extend along planes between the side parts. An internal area is formed between neighbouring flat elements, said internal areas being designed to hold the battery cells.

Battery module

The present invention relates to a housing for at least one battery module, preferably for an arrangement of battery modules, with the at least one battery module comprising a plurality of battery cells arranged in a fluid cooled frame. The invention further relates to a battery module assembly comprising at least one battery module installed in a housing.

Housing for at least one battery module and battery module assembly

A battery module assembly comprising a plurality of battery modules each comprising battery cells, with the battery modules being arranged at respective positions in at least one row and respectively having a top side at which electric contacts are provided in order to connect the plurality of battery modules to form a power supply and a bottom side, the battery module assembly further comprising a housing and a cooling plate arranged between the housing and the bottom sides of the plurality of battery modules, wherein the cooling plate comprises a plurality of separate cooling passages, wherein a heat conducting gap filling material is preferably provided directly between the bottom sides of the plurality of battery modules and the cooling plate. The invention further relates to a cooling plate for use in such a housing.

Battery module assembly and cooling plate for use in a battery module assembly

Systems and methods are provided for regulating the state of charge of a battery. An exemplary electrical system includes a fuel cell coupled to a bus and a battery coupled to the bus via a switching arrangement coupled to a capacitor. An exemplary method for operating the electrical system involves operating the switching arrangement such that a voltage of the battery is substantially equal to a voltage of the fuel cell when a state of charge of the battery is greater than a lower threshold value and less than an upper threshold value, and operating the switching arrangement to couple the capacitor electrically in series between the battery and the bus when the state of charge of the battery is not between the lower threshold value and the upper threshold value.

Switched battery and capacitor arrangement and related operating methods

Various embodiments provide two-phase boost converters. One two-phase boost converter includes a node configured to be coupled to an input voltage and a transformer coupled to the node. The transformer includes primary and secondary windings, an inductor coupled in series with the primary winding, and an inductor coupled in series with the secondary winding. Another two-phase boost converter includes an inductor configured to be coupled to an input voltage, a node coupled to the inductor, and a transformer coupled to the node. The transformer includes primary and secondary windings, an inductor coupled in series with the primary winding, and an inductor coupled in series with the secondary winding. Yet another two-phase boost converter includes a transformer coupled to first and second external inductors. The transformer includes primary and secondary windings, an inductor coupled in series with the primary winding, and an inductor coupled in series with the secondary winding.

Two-phase transformer-coupled boost converter

A system and method for controlling the voltage on a high voltage bus in a fuel cell system in response to a failed high voltage battery. The method includes determining if the high voltage battery has failed, and disconnecting the battery from the high voltage bus in response to a failure. The method measures the voltage of the fuel cell stack by a DC boost circuit and converts the measured voltage to a voltage set-point value that sets the voltage on the high voltage bus, where the voltage set-point value changes as the measured voltage changes. A supervisory controller sets the media flow to the fuel cell stack and determines a minimum stack voltage limit value based on the stack maximum current draw that is used to determine a high voltage bus lower limit value.

Method for high voltage bus control in fuel cell vehicles

A method for gathering information from battery sensors&#x2014;for instance, information regarding the state-of-charge (SOC), temperature and/or other characteristics of battery cells in a vehicle battery pack&#x2014;and using that information to estimate or predict battery degradation or state-of-health (SOH). According to an exemplary embodiment, the method uses both a time-based algorithm and an event-based algorithm to predict or estimate battery degradation. The event-based algorithm may select certain data from the battery conditions (e.g., a state-of-charge (SOC) swing (&#x394;SOC) or an SOC maximum (SOC)), instead of using the entire set of battery condition data, and may use this information in its prediction or estimate.

Method for estimating battery degradation in a vehicle battery pack

A system for reducing oscillations on a high voltage bus. The system includes a high voltage battery electrically coupled to the high voltage bus and a DC/DC boost converter electrically coupled to the high voltage bus and a fuel cell stack. The DC/DC converter includes a current controller that selectively controls the current provided by the fuel cell stack. A system controller provides a stack current set-point to the DC/DC converter. The DC/DC converter includes a voltage device that receives a voltage signal from the bus and provides a time derivative of the voltage signal that defines voltage changes on the bus over time. The time derivative signal is provided to a summer that adjusts the current stack set-point to provide a modified current set-point to the current controller that selectively adjusts the current provided by the fuel cell stack to dampen oscillations on the high voltage bus.

Method for HV bus voltage control in fuel cell vehicles featuring HV lithium batteries

A fuel cell system that employs a matched battery that matches the battery voltage to a fuel cell power bus voltage so as to eliminate the need for a DC/DC converter. The internal characteristics and parameters of the matched battery allow it to operate over the large load dependent voltage swing of the fuel cell, and prevent the battery state of charge from going below a damaging value. The battery type, number of battery cells and the battery internal impedance are selected to provide the desired matching. In one embodiment, the battery is a lithium ion battery. The system also includes a diode electrically coupled to the power bus line and a by-pass switch electrically coupled to the power bus line in parallel with the diode. The by-pass switch is selectively opened or closed to allow the fuel cell stack to recharge the battery and prevent the battery from being overcharged.

DC/DC-less coupling of matched batteries to fuel cells

A modular assembly for housing battery cells. The modular assembly includes a plurality of U-shaped members having cooling fluid channels, where the U-shaped members are mounted together in a stacked manner. Each cooling fluid channel includes an inlet and outlet orifice, where the orifices in the stacked U-shaped members align with each other. The modular assembly also includes a plurality of thermally conductive carrier plates, where a battery cell is mounted to and between opposing carrier plates. Side edges of the carrier plates are mounted in opposing retention slots in opposing U-shaped members where a cooling fluid channel in the U-shaped member is provided within the retention slot so that a cooling fluid flowing through the cooling fluid channel and the U-shaped members contacts the carrier plates and draws heat therefrom.

Modular plate carrier concept for mounting and embedded cooling of pouch cell battery assemblies

A fuel cell assembly having a terminal plate that is isolated from fluid flows passing to the fuel cell stack through manifolds is provided. A corrosion resistant member is positioned between the fuel cell stack and the terminal plate and sealingly engages with the manifold. The sealing engagement between the manifold and the corrosion resistant member prevents fluid flowing through the manifold to the fuel cell stack from contacting the terminal plate. Thus, a fuel cell assembly according to the present invention can be operated while preventing a fluid flow through the manifold from contacting the terminal plate.

Manifold sealing and corrosion preventive interface plate for a fuel cell stack

Systems and methods are provided for an on-demand boost converter for use in a vehicle. An automotive drive system comprises a boost converter having an input node, a first output node associated with a first boost leg, and a second output node associated with a second boost leg. A fuel cell is coupled to the input node of the boost converter and a battery is coupled to the first output node. An inverter module is coupled to the second output node, and a vehicle traction drive unit is coupled the inverter module. A first switch is coupled between the second output node and the first output node, wherein the battery provides energy to the second output node when the first switch is closed.

Electrical system and automotive drive system having an on-demand boost converter, and related operating methods

Systems and methods are provided for discharging a high-voltage bus using semiconductor devices. A discharge system for a first voltage rail and a second voltage rail comprises a first semiconductor device coupled to a first voltage rail and a second semiconductor device coupled between the first semiconductor device and a second voltage rail. A control circuit is coupled to the first semiconductor device and the second semiconductor device. In response to a discharge condition, the control circuit is configured to activate the first semiconductor device and gradually activate the second semiconductor device, such that the energy potential between the first voltage rail and the second voltage rail is gradually dissipated through the semiconductor devices.

Systems and methods for discharging bus voltage using semiconductor devices

A fuel cell system includes a fuel cell having conductive coolant flowing there through and a high voltage direct current (HVDC) bus interconnected with the fuel cell. An active isolation circuit includes coolant fault current sensors that detect a fault current (also called residual current) in the coolant and generates a fault signal when the fault current is detected. A switching circuit compensates and redirects the fault current based on the fault signal, providing active fault current limitation thereby.

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Egelsbach, Germany

Stephen W Raiser