Abstract:
A method of leak testing a fluid passage of a part manufactured from a low conductivity material includes measuring an electrical resistance between an interior wall surface of the fluid passage of the part, and an exterior wall surface of the fluid passage of the part. The measured electrical resistance is compared to a threshold value to determine if the measured electrical resistance is equal to or greater than the threshold value, or if the measured electrical resistance is less than the threshold value. The threshold value is equal to a nominal wall thickness of the fluid passage multiplied by a resistivity of the material used to form the part. The part passes the leak test when the measured electrical resistance is equal to or greater than the threshold value. The part fails the leak test when the measured electrical resistance is less than the threshold value.
Abstract:
A thermal management system for a rechargeable battery pack assembly includes a conduit having an upstream end and a downstream end, the downstream end operatively connectable to an enclosure of the rechargeable battery pack assembly at a port of the rechargeable battery pack assembly. A sealing mechanism is configured to transition from a first state in which the sealing mechanism blocks flow of an applied stream of water through the conduit from the upstream end through the port, to a second state in which the sealing mechanism permits flow from the upstream end to the port and through the port into the interior cavity to cool the interior cavity.
Abstract:
A method of assembling a power module includes placing a first plurality of cells adjacent to one another to form a first cell layer. A flexible circuit layer is positioned above the first cell layer, the flexible circuit being electrically conductive. A second plurality of cells is positioned adjacent to one another to form a second cell layer aligned with the first cell layer such that the flexible circuit layer is sandwiched between the first cell layer and the second cell layer. The flexible circuit layer is folded along each of a plurality of axes of rotation such that each one of the first plurality of cells faces another one of the second plurality of cells. Each of the first plurality of cells and the second plurality of cells has respective first and second tabs (extending from their respective short ends) which are welded to the flexible circuit layer.
Abstract:
A battery pack, an integrated device for sensing individual battery voltages in a battery pack and protecting the battery pack in the event of a circuit-breaking event, and a method of forming an integrated voltage-sensing circuit for use in a battery-powered automobile propulsion system. The battery pack includes numerous voltage sensing circuits with patterned sense line trace fuses and an encapsulant formed around each of the fuses. The encapsulant is robust enough to provide environmental isolation of the patterned fuse such that the tendency of the fuse to form short-circuit connections to adjacent circuits is avoided under both normal battery pack operation and after a circuit-breaking episode where the fuse blows.
Abstract:
A cooling plate design for cooling a battery cell is provided that employs a plastic plate having cutouts for coolant flow paths. The plastic plate has a layer of adhesive film on each side to maintain coolant in the channels. Compression within an alternating battery cell and coolant plate stack provides pressure that minimizes coolant load on the film. Methods to manufacture the cooling plate are also provided.
Abstract:
A cover for a battery module having a plurality of battery cells arranged in a stacked configuration includes a non-conductive main body having a plurality of spaced apart recessed regions formed therein and a plurality of electrically conductive connectors, each of the connectors disposed in one of the recessed regions and coupled to the main body.
Abstract:
A cell temperature measurement system for a battery module is described. The system may include a cell monitoring unit (CMU) configured to generate temperature measurements for a plurality of battery cells included as part of the battery module according to contactless, optical, or line-of-sight measurements made with one or more sensors associated with a temperature measurement device.
Abstract:
A rechargeable battery assembly includes battery cells, a plurality of heat spreaders, a first heat exchanger and a second heat exchanger. Each heat spreader includes a plate portion, a first end portion and a second end portion. The battery cells are disposed in a stacked arrangement, with the heat spreaders interleaved between adjacent ones of the battery cells. Fluidic channels includes a first port that is in fluidic communication with the first manifold and a second port that is in fluidic communication with the second manifold. The fluidic channels are disposed between the first and second fluidic manifolds. The stacked arrangement is interposed between the first heat exchanger and the second heat exchanger. The first end portions of the heat spreaders are in thermal contact with the first heat exchanger and the second end portions of the heat spreaders are in thermal contact with the second heat exchanger.
Abstract:
A method of assembling a power module includes placing a first plurality of cells adjacent to one another to form a first cell layer. A flexible circuit layer is positioned above the first cell layer, the flexible circuit being electrically conductive. A second plurality of cells is positioned adjacent to one another to form a second cell layer aligned with the first cell layer such that the flexible circuit layer is sandwiched between the first cell layer and the second cell layer. The flexible circuit layer is folded along each of a plurality of axes of rotation such that each one of the first plurality of cells faces another one of the second plurality of cells. Each of the first plurality of cells and the second plurality of cells has respective first and second tabs (extending from their respective short ends) which are welded to the flexible circuit layer.
Abstract:
A cooling plate design for cooling a battery cell is provided that employs a plastic plate having cutouts for coolant flow paths. The plastic plate has a layer of adhesive film on each side to maintain coolant in the channels. Compression within an alternating battery cell and coolant plate stack provides pressure that minimizes coolant load on the film. Methods to manufacture the cooling plate are also provided.