Gm Global Technolgoy Operations, Inc.

Columbia University

University of Southern California

Teijin Limited

Continental Structural Plastics, Inc.

Coats American, Inc.

Venkateshwar R Aitharaju

William R Rodgers

Selina X Zhao

Xiaosong Huang

Terrence Wathen

Erik B Golm

Bhavesh Shah

Hamid Ghavami Kia

Yutaka Yagi

Gustavo Cibrian Salazar

Dorel M Sala

Bradley Allen Newcomb

John Neal Owens

Mark A Voss

Nicholas W Pinto

Alexander Millerman

Seongchan Pack

Su Jung Han

Tsukasa Arai

Andrew J Galant

Chris James Tadeusz Wisniewski

Maria Q Feng

Princess Len Carlos

Tejas R Bhavsar

Zachariah Smith

James K Schoenow

Eleonora Maria Tronci

George Han

Colin Rowbottom

Gurpinder Dhaliwal

David E Roth

Satvir Aashat

Xiasong Huang

Ritesh Dixit

Roger G Ghanem

Luke Demo

A composite panel includes a first carbon fiber layer and a first glass fiber layer. A first carbon fiber sensor includes a first plurality of carbon fiber tows. The composite panel includes a second glass fiber layer and a second carbon fiber layer. The first carbon fiber sensor is arranged between the first glass fiber layer and the second glass fiber layer. The first carbon fiber layer and the second carbon fiber layer are arranged adjacent to the first glass fiber layer and the second glass fiber layer, respectively.

Carbon fiber composite panel with integrated fault detection and health monitoring

A method for fabricating a composite panel comprising stitching a plurality of first continuous reinforcing fibers in N first zones and M second zones of a backing substrate of a preform. The N first zones are arranged near C corners of the composite panel, where C is an integer. The plurality of first continuous reinforcing fibers in the N first zones is arranged radially relative to the C corners. At least one of a fiber density of the plurality of first continuous reinforcing fibers in the N first zones that is less than a fiber density of the plurality of first continuous reinforcing fibers in the M second zones, and a stitch density of the plurality of first continuous reinforcing fibers in the N first zones that is less than a stitch density of the plurality of first continuous reinforcing fibers in the M second zones.

Composite components and multi-zone fiber preforms for composite components

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 method for fabricating a composite panel includes providing a preform including a peripheral edge portion and a central portion. The central portion has a first thickness, the peripheral edge portion has a second thickness that is greater than the first thickness, and a first step is arranged between the central portion and the peripheral edge portion. The method includes providing a tool including a binder defining a second step, an upper punch, and a lower tool; arranging the preform between the binder and the upper punch and the lower tool; shaping the preform using the tool; and injection molding the preform in the tool to create the composite panel.

Preform with variable fiber density, forming and molding tool and method for forming of composite materials

A containment system for a rechargeable energy storage device (RESS) is described includes an enclosure having a first compartment adjoining a second compartment. The first compartment is arranged to house a plurality of power electronics devices, and the second compartment is arranged to house a plurality of battery cells. The second compartment includes a tub that defines a bottom portion, and a floor plate. The tub includes opposed end walls and opposed sidewalls. A top plate is arranged overtop of the first compartment and the second compartment. A first one of the end walls and the top plate define a first slot between the first compartment and the second compartment. A first removable panel is arranged to enclose the first compartment. The plurality of battery cells connect to the plurality of power electronics devices via a high-voltage DC power bus that is arranged to pass through the first slot.

Containment system for a multi-cell rechargeable energy storage device

A vehicle panel includes an outer panel layer formed from a first material. The outer panel layer includes a first side, a second side, and a peripheral edge. A second panel joining surface is arranged inwardly of the peripheral edge. An inner panel layer formed from a second material that is distinct from the first material is arranged across the second side. The second panel includes a first side portion, a second side portion, and a peripheral edge portion. A panel bonding layer is joined to the peripheral edge portion. The panel bonding layer is formed from a third material that is distinct from the second material. A bonding material is disposed between the second panel joining surface and the panel bonding layer creating a chemical bond between the panel bonding layer and the second panel joining surface.

Vehicle panel having a hybrid composite material construction

The present application discloses a method of making a preform for use in manufacturing a component made of a composite material. The method includes stitching fibers onto a film to form a fiber bed in a two-dimensional shape, removing the film from the fiber bed, and adjusting the fiber bed into a three-dimensional shape to form the preform.

System and method of forming a fiber preform for use in manufacturing a component made of a composite material

A battery tray is provided and includes a first component and a second component. The first component includes a first set of walls, where the first set of walls includes a first stitched fabric, and where the first stitched fabric includes first metal coated fibers. The second component includes a second set of walls, where: the second set of walls includes a second stitched fabric; the second stitched fabric includes second metal coated fibers; and the second component is attached to the first component to form the battery tray, which is configured to hold a battery pack of a vehicle. The first metal coated fibers and the second metal coated fibers provide an electromagnetic shield surrounding the battery pack.

Electromagnetic shielded battery tray with metal coated fiber stitched walls and corresponding manufacturing processes

An injection molded composite component includes a groove extending from a first surface of the composite component and a tubing material placed within the groove and formed integrally with the composite component such that the tubing material forms an integrated conduit on the first surface of the composite component.

Composite component with integrated conduit

A reinforced composite assembly includes a first sheet made of carbon fiber and having a first perimeter, a second sheet made of a non-carbon fiber material and having a second perimeter, wherein the second sheet is disposed atop the first sheet within the first perimeter, and a metallic plate having a third perimeter, wherein the metallic plate is disposed atop the second sheet within the second perimeter. The metallic plate has a plurality of holes formed therein about a perimeter of the metallic plate and defining a plurality of respective bridge portions between each of the holes and an adjacent outer edge of the metallic plate, and/or a plurality of extensions extending outward from a main portion of the metallic plate. A first arrangement of thread stitching secures each of the bridge portions and extensions to the second sheet or to the first and second sheets.

Reinforced composite assemblies and methods of manufacturing the same

A mold for molding a composite preform that has an outer edge thereabout and a plurality of tethers each attached at respective opposed ends thereof to the outer edge. The mold includes first and second mold halves defining a mold body and being configured to transition between an open position and a generally closed position, and a plurality of moveable members each having a moveable gage pin configured for being wrapped thereabout by a respective one of the tethers and a respective actuator configured for moving the moveable gage pin between a respective first position in which the respective moveable gage pin is disposed at a respective first distance from a center of the mold body and a respective second position in which the respective moveable gage pin is disposed at a respective second distance from the center of the mold body that is less than the first distance.

Mold for forming composite preforms with high precision

A composite panel for a vehicle includes a plurality of layers bonded together by resin. A sensing assembly is arranged between at least two of the plurality of layers. The sensing assembly includes at least one of a piezoelectric layer to sense vibration of the composite panel when installed on the vehicle and a thermopile configured to sense changes in temperature of the composite panel when installed on the vehicle. The sensing assembly further includes a transmitter configured to transmit data to the vehicle based on an output of the at least one of the piezoelectric layer and the thermopile.

Composite panel with a wireless, self-powered or remotely powered sensing assembly

A polymer-metal sandwich structure includes a first layer made of a polymer and having a first bonding surface, a second layer made of a metal and having a second bonding surface, and a third layer sandwiched between and in contact with the first and second bonding surfaces. The first layer contains or is capable of liberating anions of a first ion type at the first bonding surface, the second layer contains or is capable of liberating cations of a second ion type at the second bonding surface, and the third layer is made of a flame retardant formed of anions of the first ion type and cations of the second ion type. A method of manufacturing the polymer-metal sandwich structure is also provided.

Polymer-metal sandwich structure having in situ-formed flame retardant and method of manufacturing the same

A method of manufacturing a composite component according to various aspects of the present disclosure includes disposing a fiber preform in a mold. The fiber preform includes a first portion having a first edge and a second portion having a second edge. The first edge and the second edge cooperate to at least partially define a gap. One of the first portion or the second portion includes a first ferromagnetic material and the other of the first portion or the second portion includes a first magnetic or magnetizable component. The method further includes closing the gap by generating a magnetic field from the first magnetic or magnetizable component. The method further includes injecting a polymer precursor into the mold. The method further includes forming the composite component by solidifying the polymer precursor to form a polymer. The composite component includes the fiber preform and the polymer.

Composite components and methods of manufacturing composite components using magnetic forces at fiber preform seams

A mold for molding a reinforced preform having at least two apertures therein includes first and second mold halves, first and second emitters disposed in the mold halves and configured to emit light therefrom, first and second receivers disposed in the mold halves and configured to receive light from the respective first and second emitters, and first and second moving members having couplings for connection with side portions of the reinforced preform and actuators for moving the couplings between respective first and second positions. A controller determines an alignment condition based on signals received from the receivers. If the alignment condition fails to meet predetermined criteria, then at least one of the actuators is caused to move its coupling from its respective first position to a respective adjusted position that is different from the respective second position.

Growing community of inventors

Troy, MI, United States of America

Venkateshwar R Aitharaju