Gentherm Gmbh

Hyliion Inc.

Timothy Hughes

Michael Peter Ciaccio

David Scott Thomas

Alex Ho Yang

Jan Horzella

A battery pack for an electric vehicle or a hybrid vehicle may include a housing, a stack of battery cells disposed within the housing, and a cooling subassembly. The housing typically holds the cell stack together, and the cooling subassembly typically cools the cell stack to prevent damage to the battery cells and to maintain the performance of the battery cells. The cooling subassembly may include a cold plate defining a liquid flow channel and one or more thermoelectric devices (TEDs) that are operable to cool the cell stack when current is supplied thereto. Heat spreaders may be employed within the battery pack, and exemplary configurations of components to thermally and mechanically couple the cooling subassembly are described.

Battery pack optimization for thermal management

A method for manufacturing a dual conductor laminated substrate includes providing a first laminate including a first insulating layer and a first conductive layer; defining a first trace pattern including one or more traces in the first laminate; providing a second laminate including a second insulating layer and a second conductive layer; defining a second trace pattern including one or more traces in the second laminate; defining access holes in the second insulating layer; at least one of depositing and stenciling a conductive material in the access holes of the second insulating layer; and aligning and attaching the first laminate to the second laminate to create a laminated substrate.

Dual conductor laminated substrate

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 sensing system for a battery includes a flex foil substrate including a first cover layer. A conductive layer defines a trace pattern including traces. A second cover layer defines a first opening. The conductive layer is sandwiched between the first cover layer and the second cover layer. The first opening exposes a first trace and a second trace of the trace pattern. A busbar is attached to the first cover layer of the flex foil substrate. A temperature sensor is connected to the first trace and the second trace of the trace pattern in the first opening of the first cover layer.

Flex foil substrate connector for sensing battery voltage and temperature

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 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.

A battery connection assembly includes a frame including a plurality of posts that are spaced by a first distance. A flex foil includes a conductive layer and first and second insulating layers arranged adjacent to the conductive layer. A first plurality of traces is defined in the conductive layer. A plurality of fingers is defined in the conductive layer and partially released from the flex foil, wherein the first insulating layer is removed from the plurality of fingers to expose the conductive layer. A plurality of busbars is connected to the frame and including a first surface, a second surface and a hole from the first surface to the second surface. The plurality of fingers is attached to the first surfaces of the busbar at an attachment location and wherein adhesive in the hole attaches the flex foil to the busbar adjacent to the attachment location.

Growing community of inventors

South Lyon, MI, United States of America

Timothy Hughes