Abstract: A lithium-ion battery cell is preconditioned using an initial, one-time process of cell formation at an elevated temperature, or after cell formation, charge/discharge cycling for a predetermined number of cycles within a specified period of time at an elevated temperature prior to being placed in service. The process may be performed as part of manufacturing during cell formation after electrolyte filling and pre-charging. Alternatively, the pre-conditioning process may be performed after assembly of finished cells within a multi-cell battery, either before or after installation of the battery in a product, but before the battery is subjected to harsh conditions, such as fast charging and/or discharging at low temperature. An electrified vehicle may include an electric machine powered by a multi-cell lithium-ion battery preconditioned according to the initial, one-time process.

Abstract: A capacitor is configured to be in thermal contact with an electrical load. A controller is configured to charge and discharge the capacitor to change a temperature of the capacitor. The controller is configured to selectively discharge the capacitor at a discharge current at which entropic cooling of the capacitor is greater than Joule heating of the capacitor to provide cooling for the electrical load.

Abstract: A vehicle traction battery assembly may include a traction battery cell, a case, and a thermal plate. The case may define a cavity to receive the traction battery cell and has a first side defining a first form feature. The thermal plate may be for positioning adjacent the traction battery cell and define a coolant channel sized for engagement with the case via the first form feature such that traction battery cell is in thermal communication with coolant flowing through the coolant channel. The first form feature may be serpentine-shaped or S-shaped. The first form feature may be castle-shaped from a cross-sectional plan view. The case may be multi-layered and include a first polymer layer, a second polymer layer, and an aluminum layer disposed between the polymer layers.

Abstract: The disclosure provides a battery cell casing for holding a plurality of cell elements, each electrode structure in its own compartment. The disclosed casing eliminates the need for some individual cell walls and replaces them with shared wall partitions.

Abstract: A battery thermal management system includes one or more bimetallic members moveable between a first position and a second position in response to a temperature change to selectively restrict flow of a coolant through a duct.

Abstract: A vehicle including a traction battery pack, a conduit system, a sensor, an emitter, and a control system is provided. The conduit system may provide a path for coolant to enter and exit the pack and includes a conduit. The sensor may measure conditions of the pack and conduit system. The emitter may be arranged with the conduit to form a peristaltic pump. The control system may activate the pump based on sensor signals to adjust a conduit portion to influence a flow rate of the coolant flowing therethrough. The emitter may be an electromagnet to output a magnetic field. The emitter may be a voltage emitter or electric field emitter. The sensor may measure a flow rate of at least a portion of the conduit system or a temperature of the pack.

Abstract: A capacitor is configured to be in thermal contact with an electrical load. A controller is configured to charge and discharge the capacitor to change a temperature of the capacitor. The controller is configured to selectively discharge the capacitor at a discharge current at which entropic cooling of the capacitor is greater than Joule heating of the capacitor to provide cooling for the electrical load.

Abstract: A battery management controller includes input channels to receive a voltage signal from a battery and output channels to provide diagnostic signals to an operator. The controller is programmed to output a diagnostic signal predictive of a thermal condition in response to the voltage decreasing at a rate greater than a predetermined rate that signals that the voltage is decreasing toward a local minimum that precedes an increase in the voltage indicative of a battery temperature increase rate becoming greater than a threshold. The diagnostic signal may be used to alert the operator of the condition. The controller may be further programmed to issue commands to mitigate the thermal condition based on the diagnostic signal.

Abstract: A vehicle inductor assembly includes an inductor, a thermal plate, an emitter, and a controller. The inductor is secured within a housing. The thermal plate supports the inductor and includes a channel having a flexible wall with actionable particles. The emitter is located adjacent the channel. The controller is programmed to activate the emitter to impart a force upon the particles to move the wall such that a cross-sectional area of the channel is adjusted to influence a flow rate of coolant flowing therethrough. The wall may be a membrane partially secured to an interior of the channel and include the actionable particles. The actionable particles may be one of dielectric and magnetic particles and the emitter may selectively output one of a voltage, an electric field, or a magnetic field to move the dielectric or magnetic particles such that the membrane moves to adjust the cross-sectional area of the channel to influence a flow rate of coolant flowing therethrough.

Abstract: A vehicle traction battery assembly may include a traction battery cell, a case, and a thermal plate. The case may define a cavity to receive the traction battery cell and has a first side defining a first form feature. The thermal plate may be for positioning adjacent the traction battery cell and define a coolant channel sized for engagement with the case via the first form feature such that traction battery cell is in thermal communication with coolant flowing through the coolant channel. The first form feature may be serpentine-shaped or S-shaped. The first form feature may be castle-shaped from a cross-sectional plan view. The case may be multi-layered and include a first polymer layer, a second polymer layer, and an aluminum layer disposed between the polymer layers.

Abstract: Example embodiments provide systems and methods for a vehicle component structural integrity assessment system, comprising a first connection and a second connection coupled to a conduction path, which is associated with a vehicle component. The conduction path has an initial resistance. A controller is configured to transmit a signal upon the detection of a change in the resistance of the conduction path from the initial resistance.

Abstract: A vehicle inductor assembly includes an inductor, a thermal plate, an emitter, and a controller. The inductor is secured within a housing. The thermal plate supports the inductor and includes a channel having a flexible wall with actionable particles. The emitter is located adjacent the channel. The controller is programmed to activate the emitter to impart a force upon the particles to move the wall such that a cross-sectional area of the channel is adjusted to influence a flow rate of coolant flowing therethrough. The wall may be a membrane partially secured to an interior of the channel and include the actionable particles. The actionable particles may be one of dielectric and magnetic particles and the emitter may selectively output one of a voltage, an electric field, or a magnetic field to move the dielectric or magnetic particles such that the membrane moves to adjust the cross-sectional area of the channel to influence a flow rate of coolant flowing therethrough.

Abstract: A battery thermal management system includes one or more bimetallic members moveable between a first position and a second position in response to a temperature change to selectively restrict flow of a coolant through a duct.

Abstract: A hybrid thermal management system includes a battery, a capacitor, and a controller programmed to, responsive to a demand and a temperature being less than an upper threshold, select and operate only one of the battery and capacitor to satisfy the demand according to which of two values, corresponding to traction power dependent heat generation functions representing rates at which the battery and capacitor generate heat, is less to maintain the temperature below the threshold.

Abstract: A power electronics assembly may include a power electronics device, a packaging assembly, a thermal management system, and an emitter. The packaging assembly supports power electronics device. The thermal management system supports the packaging assembly and includes a thermal plate to deliver coolant for thermally communicating with the device. The thermal plate defines a channel with a wall. The emitter is arranged with the wall to form a peristaltic pump to adjust a cross-sectional area of the channel to control a flow of coolant therethrough. A membrane may be partially secured to the wall and include one of dielectric particles or magnetic particles. The emitter may selectively output one of a voltage, an electric field, or a magnetic field to impart a force on the particles to move the membrane and adjust the cross-sectional area of the channel to control a flow of coolant therethrough.

Abstract: A battery thermal management system according to an exemplary aspect of the present disclosure includes, among other things, a bimetallic member moveable between a first position and a second position in response to a temperature change to selectively restrict flow of a coolant through a duct.

Abstract: A vehicle traction battery assembly including an array of battery cells, a thermal plate, and a magnetic valve assembly. The thermal plate may be thermal communication with the array and define a flow field therein. The magnetic valve assembly may selectively output a magnetic field to tune a viscosity of magnetic coolant within a vicinity of the magnetic field and flowing within the flow field to promote or inhibit the flowing within the flow field. The flow field may include first and second channels and the magnetic valve assembly may further selectively output the magnetic field to tune the viscosity such that the magnetic coolant flows through the second channel and not the first channel.

Abstract: A vehicle including a traction battery pack, a conduit system, a sensor, an emitter, and a control system is provided. The conduit system may provide a path for coolant to enter and exit the pack and includes a conduit. The sensor may measure conditions of the pack and conduit system. The emitter may be arranged with the conduit to form a peristaltic pump. The control system may activate the pump based on sensor signals to adjust a conduit portion to influence a flow rate of the coolant flowing therethrough. The emitter may be an electromagnet to output a magnetic field. The emitter may be a voltage emitter or electric field emitter. The sensor may measure a flow rate of at least a portion of the conduit system or a temperature of the pack.

Abstract: Example embodiments provide systems and methods for a vehicle component structural integrity assessment system, comprising a first connection and a second connection coupled to a conduction path, which is associated with a vehicle component. The conduction path has an initial resistance. A controller is configured to transmit a signal upon the detection of a change in the resistance of the conduction path from the initial resistance.

Abstract: A power electronics assembly may include a power electronics device, a packaging assembly, a thermal management system, and an emitter. The packaging assembly supports power electronics device. The thermal management system supports the packaging assembly and includes a thermal plate to deliver coolant for thermally communicating with the device. The thermal plate defines a channel with a wall. The emitter is arranged with the wall to form a peristaltic pump to adjust a cross-sectional area of the channel to control a flow of coolant therethrough. A membrane may be partially secured to the wall and include one of dielectric particles or magnetic particles. The emitter may selectively output one of a voltage, an electric field, or a magnetic field to impart a force on the particles to move the membrane and adjust the cross-sectional area of the channel to control a flow of coolant therethrough.