Gm Global Technolgoy Operations, Inc.

Visteon Global Technolgoies, Inc.

Tao Wang

Mei Cai

Fang Wang

Fiona E Meyer-Teruel

Theodore T Kim

Mahmoud H Abd Elhamid

Tao Xie

Fang Dai

Jeffrey Johnson

Thomas John Timpf, Jr

Xiaosong Huang

Li Yang

Larry T Nitz

Chih-Cheng Hsu

Robert S Conell

Sherman H Zeng

Andrew C Baughman

Jingmei Shen

Leo Francis Schwab

Phillip D Hamelin

Ramona Y Ying

Zhongying Shi

Michael P Barker

Yan Wu

Charles A Campbell

Fan Xu

Mohammed Bahauddin

William J Wallace

Helen X Qin

Kai Zhuang

Julien Payan

Tamara R Thomson

Wayne Z Ptasinski

Simon T Dunmore

Janpreet S Basi

A power converter incudes a power factor correction circuit and a controller. The power factor correction circuit is configured to convert an input single-phase electrical power to a first DC electrical power. An active phase of the input single-phase electrical power is received in parallel through two of four conductors. A return phase of the input single-phase electrical power is received in parallel through two others of the four conductors. The power factor correction circuit is also configured to convert an input three-phase electrical power to the first DC electrical power. Three active phases of the input three-phase electrical power are received through three of the four conductors. The return phase is received through a fourth of the four conductors. The controller is configured to control the power factor correction circuit to operate in the single-phase input mode and the three-phase input mode in response to a control signal.

Variable-phase power converter

A battery system includes a rechargeable energy storage system (RESS) having battery cells, and a battery controller network configured to execute two-level logic to detect a thermal runaway condition. The network includes RESS-embedded cell monitoring units (CMUs) electrically connected to a respective cell group, and measuring and wirelessly transmitting cell data. A battery control module (BCM) is in communication with the CMUs. Thermal runaway sensors are mounted on the CMUs and/or the BCM. A master controller connected to the BCM includes a thermal runaway detection algorithm configured to detect a thermal runaway condition occurring within the RESS. The BCM uses data from the CMUs and thermal runaway sensors to execute first logic level which determines when to wake up the master controller. The master controller, in response to receipt of a wakeup signal, executes a second logic level to execute the algorithm.

Two-level method for thermal runaway detection

A thermal insulation component according to various aspects of the present disclosure includes a matrix, a crosslinking precursor, and a crosslinking initiator. The matrix includes a thermal insulation material having a thermal conductivity of less than or equal to about 5 W/mK. The crosslinking precursor is embedded in the matrix. The crosslinking precursor includes at least one of an acrylate functional group or a methacrylate functional group. The crosslinking initiator is embedded in the matrix. The crosslinking initiator is configured to decompose to initiate crosslinking of the crosslinking precursor. In certain aspects, the present disclosure also provides an electronics assembly including an electronic component and a thermal insulation material in thermal communication with the electronic component. In certain aspects, the present disclosure also provides methods of manufacturing the thermal insulation component.

Thermal insulation components and methods of manufacturing thermal insulation components

A monitor and control system and a method of monitoring and controlling an onboard system of an assembly includes one or more of a plurality of sensors detects whether an event occurred in the onboard system. The sensors communicate with a master controller when the master controller is in a nominal mode in which the master controller is powered on to actively monitor the sensors, and includes a sleep mode in which the master controller is powered off and does not monitor the sensors when in the sleep mode. An agent controller monitors the sensors when the master controller is in the sleep mode. One or more of the sensors signal the agent controller that the event has occurred. The agent controller signals the master controller to awaken from the sleep mode in response to the one or more of the sensors signaling the agent controller of the event.

Method of monitoring and controlling an onboard system and a monitor and control system

A battery system includes a battery module, an active cell balancing circuit, and a battery controller. Each cell has diametrically-opposed positive and negative cell tabs. The circuit includes voltage sensors and, at each end of the battery module, first and second tiers of switches and an energy storage element. Each voltage sensor is located between a different pair of adjacent cells. The controller receives measured voltages from the sensors indicative of an electric potential between adjacent battery cells. Responsive to the measured voltages, the controller commands the first tier to selectively connect or disconnect designated pairs of cells to the corresponding second tier. The controller also commands the second tier to selectively connect or disconnect the designated cells to a corresponding energy storage element. This action shuttles energy between the designated pairs of battery cells to balance a state of charge.

Battery module with active cell balancing using energy storage element and two tiers of switches

A high-voltage electrical system includes a high-voltage electrical bus, a low-voltage controller performing battery management system (BMS) functions, and a rechargeable energy storage system (RESS) connected to the HV electrical bus. The RESS has contactors connected to the voltage rails, a battery pack, a current sensor outputting a voltage signal indicative of pack current, cell monitoring units (CMUs) connected to designated battery cells that measure corresponding cell voltages, and voltage isolation hardware between the CMUs and the LV controller. The voltage isolation hardware includes the contactors and may include a transformer. The RESS and LV controller are connected via LV serial connections such that the LV controller performs the designated BMS functions, including monitoring the pack current and controlling an open/closed state of the contactors. A powertrain system includes the electrical system, an electric machine, and a coupled load.

High-voltage system with low-voltage control architecture and method

The present disclosure provides a battery pack component including a self-healing coating. The self-healing coating is disposed on at least a portion of a surface of the battery pack component. The self-healing coating includes a first precursor including a cyclic ether capable of reacting in a self-healing cationic ring-opening polymerization reaction. The self-healing coating further includes an initiator including an alkali metal salt. The self-healing cationic ring-opening polymerization reaction occurs when a defect is present in the self-healing coating. In certain aspects, the cyclic ether may include 1,3-dioxolane (CHO) and the initiator may include lithium bis(fluorosulfonyl)imide (FNaNOS). In other aspects, the self-healing coating may include a second precursor that is capable of copolymerizing with the first precursor. In still other aspects, the present disclosure provides a method of making a self-healing coating for a battery pack component.

Living cationic ring-opening polymerization (c-ROP) self healing coating for battery module packaging in electric vehicles (EV)

A battery module for use with a controller includes a printed circuit board assembly (PCBA) mounted to a plurality of battery cells. The PCBA includes a substrate, a radio frequency (RF) communications circuit, a cell sensing circuit, and a conductive interconnecting member. The cell sensing circuit is operable for measuring a respective cell voltage of each of the battery cells. The conductive interconnect member forms an electrical connection between the battery cells. The RF communications circuit is in wireless communication with the controller and is operable for wirelessly transmitting the measured cell voltages to the controller. A battery system includes a master battery controller and the battery pack. A vehicle includes an electric machine operable for generating output torque for propelling the vehicle, as well as the battery system noted above.

Battery module with integrated RF communication and cell sensing board

Examples of battery pack systems that include polymers are a cooling system, a thermal management system, and a liquid leakage control system. The cooling system and the thermal management systems may include an upper critical solution temperature polymer or a lower critical solution temperature polymer. The liquid leakage control system includes a superabsorbent polymer.

Battery pack systems that include polymers

A method and device for improving a structurally integrated propulsion battery system with a battery, a tray for accommodating the battery, with lower and upper internal structural cross beams coupled to the tray, and a liquid cooling plate located between the upper internal structural cross beam and the lower internal structural cross beam.

Structurally integrated propulsion battery

Methods and systems for depowering an automotive battery in a controlled manner. The methods comprise (i) providing a depowering medium comprising one or more non-ionic electric conductors (for example, a carbon conductor) dispersed in a substantially non-ionic aqueous medium; (ii) contacting terminals of the battery with the depowering medium; and (iii) maintaining contact between the depowering medium and terminals for a period of time sufficient to depower the battery. The systems comprise (i) the depowering medium; and (ii) a container configured to receive a battery and the depowering medium such that the battery body is contacted with the depowering medium prior to the terminals.

System and methods for controlled depowering of automobile batteries

Methods and systems for depowering a rechargeable battery in a rapid, yet controlled, manner. The methods comprise (i) providing a depowering medium comprising expanded graphite (and optionally, one or more dispersible non-ionic electric conductors) dispersed in a substantially non-ionic aqueous medium; (ii) contacting terminals of the battery with the depowering medium; and (iii) maintaining contact between the depowering medium and terminals for a period of time sufficient to depower the battery. The systems comprise (i) the depowering medium; and (ii) a container configured to receive a battery and the depowering medium such that the battery body is contacted with the depowering medium prior to the terminals.

Cost-effective reliable method to depower rechargeable electric batteries

Growing community of inventors

Oakland Township, MI, United States of America

Tao Wang