Abstract: Methods and systems are provided for a battery system which comprises a plurality of battery cells housed inside a battery enclosure of a battery pack, a venting system, and a suppressing agent. The venting system comprises a dual-staged venting valve that equalizes pressure during normal operation of the battery system and a vent valve that opens to relieve pressure during a high pressure or temperature event. The suppressing agent is released into the enclosure of the battery pack to reduce further reactions by removing or limiting oxidants within the battery pack. A solenoid is coupled to the dual-staged venting valve and seals the dual-staged venting valve following release of the suppressing agent, allowing for the suppressing agent to remain in the enclosure for a longer period of time in order to provide increased mitigation of future thermal events in the battery enclosure.

Abstract: Systems and methods for electric motor cooling. The cooling system, in one example, includes a sealing ring coupled to or formed in a stator and including a flange that axially extends outward from an axial side of the stator. The cooling system further includes a first sealing sleeve with a first sealing interface that is formed between the sealing sleeve and a motor housing and a second sealing interface that is formed between the sealing sleeve and the flange, where a cavity is formed between the sealing sleeve and the sealing ring in which a stator end winding is at least partially immersed in a coolant.

Abstract: A method and system are provided for a fastening system comprising: an electrically conductive continuous unitary structure, such as an electrically conductive stud, overmolded into an enclosure, the electrically conductive stud extending from an interior of the enclosure to an exterior of the enclosure. The fastening system may act as a structural member transferring mechanical forces away from the battery enclosure, secure the battery enclosure to a mount, aid in sealing the battery enclosure, and act as an electrical grounding path for the battery through an enclosure formed of a non-electrically conductive composite material.

Abstract: Methods and systems are provided for a battery cooling enclosure. In one embodiment, the battery cooling enclosure may be incorporated in an electric vehicle and may comprise battery cooling system, including a first support rail with a first coolant inlet, a second support rail with a first coolant outlet, and a plurality of cold plate slots arranged in parallel between the first support rail and the second support rail. Each slot of the plurality of cold plate slots is coupled to a first fluid passage of the first support rail and a second fluid passage of the second support rail. The battery cooling system of the battery cooling enclosure may thus allow for cooling of a battery using a variable amount of cold plates.

Abstract: A battery coolant heater assembly including a coolant manifold having liquid coolant pathways and a heat transfer surface for transferring heat to liquid coolant flowable within the coolant manifold, an electric heater element thermally contacted to the heat transfer surface of the manifold, and a cover sealably enclosing the heating element between the heat transfer surface and the cover via a gasket. The electric heater element is electrically connected via an electrical connector extending through and formed integrally with the gasket.

Abstract: A system may comprise a first plate arranged directly against a second plate and defining a gasket groove, the plates each parallel to one another and to a plane; and a gasket formed in a plane and having a sinusoidal variation in a direction normal to the plane. The first and second plate may form a bipolar plate and may be used as a component of a fuel cell. The section of the gasket with sinusoidal variation may be fit to the groove. The gasket may have a bead that may fit to a fitting, such as a gasket, on another plate or surface to seal the contents of a fuel cell.

Abstract: Methods and system are provided for a discharge system. In one example, an emergency response vehicle, comprising a battery discharge system having a charging connector configured to electrically couple a capacitor of the emergency response vehicle to a battery of an electric vehicle.

Abstract: A battery coolant heater assembly including a coolant manifold having liquid coolant pathways and a heat transfer surface for transferring heat to liquid coolant flowable within the coolant manifold, an electric heater element thermally contacted to the heat transfer surface of the manifold, and a cover sealably enclosing the heating element between the heat transfer surface and the cover via a gasket. The electric heater element is electrically connected via an electrical connector extending through and formed integrally with the gasket.

Abstract: A battery coolant heater assembly including a coolant manifold having liquid coolant pathways and a heat transfer surface for transferring heat to liquid coolant flowable within the coolant manifold, an electric heater element thermally contacted to the heat transfer surface of the manifold, and a cover sealably enclosing the heating element between the heat transfer surface and the cover via a gasket. The electric heater element is electrically connected via an electrical connector extending through and formed integrally with the gasket.

Abstract: Methods and systems are provided for a fastener for a battery casing. In one example, the fastener may include a bolt inserted into a sleeve to align and secure parts of a battery casing. The sleeve may be a continuous, unitary structure that may be shaped as a dowel pin and may include a nut and torque limiter.

Abstract: Methods and systems are provided for a cold-plate. In one example, a method comprises laser welding a tray to a frame, wherein a gasket is arranged between beads of the laser welding.

Abstract: Methods and system are provided for a discharge system. In one example, an emergency response vehicle, comprising a battery discharge system having a charging connector configured to electrically couple a capacitor of the emergency response vehicle to a battery of an electric vehicle.

Abstract: A gasket with at least one integral electrical connector adapted for an assembly includes an elastomeric gasket main body adapted to seal a joint between one or more assembly components and a cover, and at least one electrical connector extending through and formed integrally with the elastomeric gasket main body so as to provide power or electric signals to at least one electrical component of the assembly.

Abstract: A battery coolant heater assembly including a coolant manifold having liquid coolant pathways and a heat transfer surface for transferring heat to liquid coolant flowable within the coolant manifold, an electric heater element thermally contacted to the heat transfer surface of the manifold, and a cover sealably enclosing the heating element between the heat transfer surface and the cover via a gasket. The electric heater element is electrically connected via an electrical connector extending through and formed integrally with the gasket.

Abstract: A component for an electrochemical cell is formed by additive manufacturing process. The additive manufacturing process can be repeated to produce fuel cell stack.

Abstract: A two material joint design may be made of a first piece made of a first material. The first piece including a first mating portion of a joint. The design may also have a second piece made of a second material. The second material is different than the first material. The second piece includes a second mating portion of the joint complementary in shape to the first mating portion.

Abstract: A component for an electrochemical cell is formed by additive manufacturing process. The additive manufacturing process can be repeated to produce fuel cell stack.

Abstract: A two material joint design is provided. The design may be made of a first piece made of a first material. The first piece including a first mating portion of a joint. The design may also have a second piece made of a second material. The second material is different than the first material. The second piece includes a second mating portion of the joint complementary in shape to the first mating portion.

Abstract: A gasket is provided with two dissimilar materials. The two different materials are used to provide different sealing characteristics. In one embodiment, the different sealing materials join to create the same or a similar profile to the profile of the individual materials. In another embodiment, the different sealing materials have the same profile but have joining portions that are complementary to one another where the two materials are joined to one another.