Gm Global Technolgoy Operations, Inc.

Su Jung Han

Seongchan Pack

Martin Stephen Kramer

Grant William Brady

David R Clark

Julie A Swartz

Gustavo Cibrian Salazar

Xiaosong Huang

Taeyoung Han

Anthony M Coppola

Chih-Hung Yen

Bradley Allen Newcomb

Kuo-Huey Chen

Venkateshwar R Aitharaju

Bhavesh Shah

Song He

Peter P Andruskiewicz, Iv

Alexander M Bilinski

Ryan P Hickey

Lokesh Choudhary

Qinglin Zhang

Phillip D Hamelin

Chijou Wang

Brian W Geiser

Raviraj U Nayak

Sharon Xiaobin Li

Brian Christopher Leuenhagen

Cara A Koepele

A hybrid material housing for a battery reduces or minimizes thermal runaway propagation. The housing includes a composite structure for the battery and optionally includes a polymeric matrix selected from the group consisting of: epoxy, phenolic resin, polyester, vinyl ester, and combinations thereof and a reinforcing material selected from the group consisting of: glass fibers, carbon fibers, basalt fibers, aromatic polyamide KEVLAR® fibers, and combinations thereof. A metal layer is disposed along an exterior surface of the composite structure that comprises aluminum, steel, stainless steel, alloys, and combinations thereof. In a first mode, the metal layer contacts the composite structure and in a second mode after exposure to a thermal load of greater than or equal to about 500° C., the metal layer at least partially delaminates from the exterior surface and forms insulating air gaps to define a thermal barrier. Methods of forming the hybrid material housings are also provided.

Hybrid composite materials systems for battery housings having improved thermal performance

A battery includes a battery cell stack disposed within a housing such that a gap exists between the battery cell stack and an inner surface of the housing. The battery cell stack includes a plurality of battery cells that each include a positive electrode tab and a negative electrode tab electrically coupled to an electrode assembly and extending from the electrode assembly outside of a case. The positive electrode tabs and/or the negative electrode tabs of the plurality of battery cells extend into the gap between the battery cell stack and the inner surface of the housing. A filler material fills the gap and provides a thermally conductive pathway between the positive electrode tabs and/or the negative electrode tabs of the plurality of battery cells and the inner surface of the housing. The filler material includes a thermally conductive particulate component distributed throughout a polymeric matrix component.

Battery including thermally conductive filler material with thermal runaway containment function

Disclosed herein is a battery module comprising a plurality of battery cells encased in an outer shell. The outer shell has disposed on an inner surface a flame retardant layer that comprises expandable graphite. The expandable graphite is operative to expand during an thermal event that results in an increase in battery module temperature. Disclosed herein too is a method comprising disposing in a battery module a flame retardant layer; where the battery module comprises a plurality of battery cells encased in an outer shell. The outer shell has disposed on an inner surface a flame retardant layer that comprises expandable graphite. The expandable graphite is operative to expand during an thermal event that results in an increase in battery module temperature.

Flame-retardant compositions for energy storage devices, methods of manufacture thereof and batteries containing the same

A method of creating an interface includes: a) adding organometallic compounds to a polymeric material to create an interfacial layer; b) placing the polymeric material having the interfacial layer in a mold; c) heating a deposit material until the deposit material has a predetermined-minimized volumetric density; and d) depositing the deposit material on the interfacial layer. The latent heat of the molten metallic material transfers to the interfacial layer to create chemical bonds and physical interlocks between the interfacial layer and the metallic material. The deposit material cools to form solidified layer on the interfacial layer.

Enthalpy-driven self-hardening process at the polymeric/metal layer interface with an interdiffusion process

A multi-module battery pack includes a battery tray defining multiple battery tray compartments, battery modules each disposed within a corresponding one of the compartments, and a thermal barrier arranged in a predefined heat transfer path through the tray between an adjacent pair of the battery modules. The thermal barrier has a thickness of at least about 1 mm and a thermal conductivity of less than about 4 W/m-K, such that the thermal barrier blocks the heat transfer path to mitigate a thermal runaway event of one of the adjacent pair of battery modules. An electric powertrain system includes a rotary electric machine having phase leads and an output member, a driven load coupled to the output member, and the multi-module battery pack. A method includes providing the tray, identifying the heat transfer path, and arranging the thermal barrier in the heat transfer path.

Electric powertrain system with multi-module battery pack and intermodule thermal barrier

An electrochemical assembly includes a case defining an interior region, an electrochemical cell, a device, and a pressure relief valve. The electrochemical cell is disposed within the interior region. The device includes a spreader component. The spreader component includes a polymer matrix and an additive embedded in the polymer matrix. The additive includes an endothermic phase change material, a flame retardant material, an intumescent material, or any combination thereof. The device defines a device outlet. The pressure relief valve has a valve inlet fluidly connected to the interior region and a valve outlet fluidly connected to the device. The pressure relief valve is configured to transfer a gas from the interior region to the device when a pressure in the interior region exceeds a predetermined pressure. The spreader component is configured to be in fluid communication with the gas and direct the gas to the device outlet.

Temperature and spark reduction device

An exemplary method of depositing a layer of a material on an interior substrate surface of a complex geometry component includes the steps of providing the complex geometry component having an aperture defining an edge of the interior substrate surface of the complex geometry component, at least a portion of the interior substrate surface defining a first area not visible from the aperture, providing a heating element adjacent to the first area of the complex geometry component, energizing the heating element to raise a surface temperature of the first area and establish a thermal gradient between the first area and an adjacent area, and providing a vapor deposition apparatus configured to deposit the layer of material on the interior substrate surface corresponding to the first area of the complex geometry component.

Systems and methods for improved vapor deposition on complex geometry components

A linerless engine block includes a polymer matrix composite having an internal surface that defines a bore. The polymer matrix composite has a first thermal conductivity at the internal surface of at least 5 W/m&#xb7;&#xb0; C. The linerless engine block also includes a first bond coating disposed on the internal surface within the bore, and a second wear-resistant coating disposed on the first bond coating within the bore such that the second wear-resistant coating is adhered to the polymer matrix composite by the first bond coating. A method of forming the linerless engine block is also described.

High-temperature, wear-resistant coating for a linerless engine block

A turbine wheel for a turbocharger of a vehicle propulsion system includes a central hub and a plurality of blades extending outwardly from the central hub. Each of the blades defining an inducer section and an exducer section, and each of the blades including a first surface portion and a second surface portion. The first surface portion including a thermal barrier coating and the second surface portion free from the thermal barrier coating.

Thermal barrier coated vehicle turbocharger turbine wheel

A composite article configured for mitigating noise, vibration, and harshness includes a substrate having a first stiffness. The composite article includes a structural film formed from a composition and disposed on the substrate in a pattern that is arranged to dampen a sound wave having a first frequency and a first amplitude and propagatable in a first direction to a second frequency that is less than the first frequency and a second amplitude that is less than the first amplitude. The composite article includes a coating layer disposed on the pattern and configured to dampen the sound wave in the first direction and in a second direction that is perpendicular to the first direction. The composite article has a second stiffness that is greater than the first stiffness. A method of forming the composite article is also described.

Composite article for mitigating noise, vibration, and harshness

An integrated power electronics component configured for mitigating noise, vibration, and harshness includes a case formed from metal and configured to dampen a sound wave having a first frequency and a first amplitude and propagatable in a first direction. The case has a first surface and a second surface spaced apart from the first surface, a first stiffness, and a first strength, and the first and second surfaces include a structure defining a plurality of recessions therein. The component includes a cured polymer formed from a composition disposed on at least one of the first and second surfaces in each of the recessions to thereby dampen the sound wave in the first direction and in a second direction that is perpendicular to the first direction to a second frequency that is less than the first frequency and a second amplitude that is less than the first amplitude.

Integrated power electronics component for mitigating noise, vibration, and harshness

A cylinder block for use in an internal combustion engine includes a first and second cylinder bores, a first and second cylinder bore liners, and a Siamese insert. The first and second cylinder bores are disposed adjacent to each other. The first and second cylinder bores each comprise a first cylinder bore wall and a second cylinder bore wall, respectively, and a shared cylinder bore wall. The first cylinder bore liner is disposed on a first inner surface of the first cylinder bore wall and the second cylinder bore liner is disposed on a second inner surface of the second cylinder bore wall. The Siamese insert is disposed in a top portion of the shared cylinder bore wall.

Method of manufacturing an engine block

A vehicle system includes a vehicle component, a battery, and a thermoelectric module coupled to the component to allow heat transfer between the catalytic converter and the thermoelectric module, wherein the thermoelectric module is electrically connected to the battery. The vehicle system further includes a temperature sensor coupled to the vehicle component. The temperature sensor is configured to measure the temperature of the vehicle component. The vehicle system further includes a controller in electronic communication with the thermoelectric module. The controller is programmed to switch the thermoelectric module among the heating mode, the cooling mode, and the power-generation mode based on the temperature of the vehicle component. The vehicle component may be an exhaust manifold, a turbocharger turbine housing, an exhaust gas conduit coupled between an exhaust manifold and a catalytic converter, and/or a catalytic converter.

Growing community of inventors

West Bloomfield, MI, United States of America

Su Jung Han