公开(公告)号：US20230142691A1

公开(公告)日：2023-05-11

申请号：US17472210

申请日：2021-09-10

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Venkateshwar R. AITHARAJU ,  Xiaosong HUANG ,  Bhavesh SHAH ,  Gustavo Cibrian SALAZAR ,  Su Jung HAN

IPC: H01M50/231 ,  H01M50/209 ,  H01M50/227 ,  H01M50/224 ,  H01M50/233

CPC classification number: H01M50/231 ,  H01M50/209 ,  H01M50/224 ,  H01M50/227 ,  H01M50/233

Abstract: A hybrid material housing for a battery is provided for reducing or minimizing thermal runaway propagation. The housing includes a composite structure that contains 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.

公开(公告)号：US20250023169A1

公开(公告)日：2025-01-16

申请号：US18352031

申请日：2023-07-13

Applicant: GM Global Technology Operations LLC

Inventor： Venkateshwar R. AITHARAJU ,  Xiaosong Huang

IPC: H01M50/229 ,  H01M10/658 ,  H01M50/224 ,  H01M50/231

Abstract: An enclosure for one of a battery module or battery pack includes a body configured to receive at least one of a plurality of battery modules and a plurality of battery cells. A cover is arranged over the body and includes an outer metallic layer, a composite layer arranged adjacent to an inner surface of the outer metallic layer and including reinforcing fibers encapsulated in resin, and a coating layer arranged on an inner surface of the composite layer and including a molecular nitrogen releasing agent.

公开(公告)号：US20240140052A1

公开(公告)日：2024-05-02

申请号：US17977083

申请日：2022-10-31

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Venkateshwar R. AITHARAJU ,  Erik Brandon GOLM ,  Xiaosong HUANG

IPC: B29C70/34 ,  B29C45/00 ,  B29C45/14 ,  B29C45/80 ,  B29C70/06

CPC classification number: B29C70/345 ,  B29C45/0005 ,  B29C45/14008 ,  B29C45/14221 ,  B29C45/80 ,  B29C70/06 ,  B29L2007/002

Abstract: 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.

公开(公告)号：US20240391187A1

公开(公告)日：2024-11-28

申请号：US18322178

申请日：2023-05-23

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC ,  Coats American Inc

Inventor： Venkateshwar R. AITHARAJU ,  Selina Xinyue Zhao ,  George Han ,  Colin Rowbottom

IPC: B29C70/54 ,  B29C70/46

Abstract: 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.

公开(公告)号：US20220190434A1

公开(公告)日：2022-06-16

申请号：US17119585

申请日：2020-12-11

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Venkateshwar R. AITHARAJU ,  Xiaosong HUANG ,  Bhavesh SHAH ,  Gustavo CIBRIAN SALAZAR

IPC: H01M50/367 ,  H01M50/16 ,  H01M50/164 ,  H01M50/157

Abstract: The present disclosure relates to composite battery covers including one or more integral vent members configured to release pressure. An example composite battery cover includes a continuous sheet having a first stiffness and one or more vent members defined in the continuous sheet. Each of the one or more vent members may include a first area having a second stiffness and/or a second area having a third stiffness. The second stiffness may be different from the first stiffness. The third stiffness may be different from the second stiffness and/or the first stiffness. The stiffness and strength of the continuous sheet and/or one or more vent members may be controlled by variable thicknesses and/or fiber loadings.

公开(公告)号：US20220134607A1

公开(公告)日：2022-05-05

申请号：US17085497

申请日：2020-10-30

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Venkateshwar R. AITHARAJU ,  Princess Len M. CARLOS ,  Donald E. MATTHEWS

IPC: B29C35/08 ,  B29B11/12 ,  B29B11/16

Abstract: A method of fabricating a preform is provided. The method includes disposing a veil over a first mold portion having a three-dimensional shape, the veil including a thermoplastic material and magnetic particles; disposing a fiber tow onto the veil; heating at least a portion of the veil by induction so that the fiber tow becomes coupled to the veil; compressing the fiber tow and the veil toward each other with a second mold portion that has a negative contour relative to the first mold portion; and removing the preform from the first and second mold portions. The preform has the three-dimensional shape and includes the fiber tow coupled to the veil. Preforms prepared by the method are also provided.

公开(公告)号：US20210229327A1

公开(公告)日：2021-07-29

申请号：US16773516

申请日：2020-01-27

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Venkateshwar R. AITHARAJU ,  William R. RODGERS ,  Selina X. ZHAO ,  Terrence WATHEN

IPC: B29C45/14 ,  B29C31/00 ,  B29C33/16 ,  B29C33/32 ,  H01F1/04

Abstract: 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.

公开(公告)号：US20230407531A1

公开(公告)日：2023-12-21

申请号：US17840845

申请日：2022-06-15

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Venkateshwar R. AITHARAJU ,  Bhavesh SHAH ,  Xiaosong HUANG

IPC: D02J1/18 ,  B29C70/08 ,  B29C70/10

CPC classification number: D02J1/18 ,  B29C70/08 ,  B29C70/10 ,  B29L2031/7146

Abstract: A composite component includes a substrate including a first region and a second region. A plurality of first fiber tows is arranged in the first region and including non-conductive filaments. First stitches attach the plurality of first fiber tows to a first surface of the substrate. A plurality of second fiber tows are arranged in the second region and including conductive filaments. Second stitches attach the plurality of second fiber tows to the first surface of the substrate.

公开(公告)号：US20230402685A1

公开(公告)日：2023-12-14

申请号：US17835612

申请日：2022-06-08

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Venkateshwar R. AITHARAJU ,  Xiaosong HUANG

IPC: H01M50/126 ,  H01M50/375 ,  H01M50/383 ,  H01M50/367

CPC classification number: H01M50/126 ,  H01M50/375 ,  H01M50/383 ,  H01M50/367 ,  H01M2200/10

Abstract: The present disclosure provides a composite material housing for a battery pack for reducing or minimizing thermal runaway propagation. The composite material housing includes a polymeric structure defining an interior-facing surface and an exterior-facing surface. The polymeric structure includes a fire resistant material layer and a reinforcing material layer, where the fire resistant material layer defines an interior-facing surface, and the reinforcing material layer defines the exterior-facing surface. The composite material further includes a metallic layer disposed along the exterior-facing surface, where in a first operational mode the metallic layer contacts the exterior-facing surface and in a second operational mode, after exposure to a thermal load of greater than or equal to about 500° C., the metallic layer at least partially delaminates from the exterior-facing surface and forms one or more insulating air gaps that define a thermal barrier.

公开(公告)号：US20220324310A1

公开(公告)日：2022-10-13

申请号：US17226942

申请日：2021-04-09

Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC

Inventor： Venkateshwar R. AITHARAJU ,  Gurpinder S. DHALIWAL ,  Erik B. GOLM ,  Princess Len M. CARLOS ,  Donald E. MATTHEWS ,  James K. SCHOENOW

IPC: B60J5/10 ,  B32B7/09 ,  B32B5/06 ,  B32B15/02 ,  B32B15/14

Abstract: The present disclosure provides a composite lift gate for a vehicle. The composite lift gate includes a polymer matrix and a fiber assembly. The fiber assembly is embedded in the polymer matrix. The fiber assembly includes a fiber mat and a plurality of substantially-aligned continuous fibers. The plurality of substantially-aligned continuous fibers is directly connected to a portion of the fiber mat. In one aspect, the composite lift gate further includes an electronic component connected to the fiber assembly. In various aspects, the present disclosure provides a method of manufacturing a composite lift gate for a vehicle.