Abstract: A traction battery assembly for a vehicle is provided. The traction battery assembly may include a plurality of battery cells and a thermal plate positioned beneath the battery cells. The thermal plate may be configured for thermal communication with the plurality of battery cells. The thermal plate may define a plurality of multi-pass channel configurations, each corresponding to one of the battery cells. The multi-pass channel configurations may each include a channel inlet and channel outlet on opposite side portions of the thermal plate. The multi-pass channel configurations may each be configured to direct thermal fluid flowing therein to an outlet port of the thermal plate without directing fluid to the channel inlet of another channel configuration.

Abstract: A traction battery assembly for a vehicle is provided. The traction battery assembly may include a battery cell array and a thermal plate configured to support the battery cell array. The thermal plate may define an inlet port, two outer channels each having a channel inlet in communication with the inlet port, at least three inner channels disposed between the outer channels, and an outlet port. The ports and channels may be arranged such that fluid traveling through any two adjacent channels flows in opposite directions and fluid, when exiting the thermal plate, empties from one or more of the inner channels into the outlet port without first entering the channel inlets.

Abstract: A traction battery assembly for a vehicle is provided. The traction battery assembly may include a battery cell array having a plurality of battery cells. A thermal plate may be positioned beneath the battery cells and be configured for thermal communication therewith. The thermal plate may define a plurality of channel configurations within the thermal plate. Each of the channel configurations may correspond to one of the battery cells and include an inlet and outlet on a same side portion of the thermal plate. An inlet plenum may be in communication with the inlets and an outlet plenum may be in communication with the outlets. The channel configurations and plenums may be arranged such that fluid exiting the inlet plenum enters the channel configurations via the outlets and fluid exiting the outlets enters the outlet plenum and not into the inlet of another one of the channel configurations.

Abstract: A traction battery assembly includes a battery array with a plurality of stacked cells and a serpentine heat exchanger. The heat exchanger defines passageways for coolant to flow therethrough. The heat exchanger is interleaved with the cells such that opposite sides of each of the cells are in contact with the heat exchanger.

Abstract: A modular thermal management system for a battery in an electric vehicle is provided. In one embodiment, a modular thermal management system for a battery in an electric vehicle is provided. The modular system includes a plurality of manifold segments. Each of the manifold segments further comprises a plurality of fluid ports adapted to connect to a heat exchanger fin for a battery cell. Each manifold segment corresponds to a battery stack comprised of a plurality cells and heat exchanger fins. At least one manifold clip is provided for securing two adjacent manifold segments together. The manifold clip bridges the coupling joint and engages retention features on each of the two manifold segments in order to inhibiting separation longitudinally between the two manifold segments. A plurality of manifold clips are configured to secure a plurality of manifold segments together accommodate a plurality of battery stack configurations.

Abstract: A modular thermal management system for a battery in an electric vehicle is provided. In one embodiment, a modular thermal management system for a battery in an electric vehicle is provided. The modular system includes a plurality of manifold segments. Each of the manifold segments further comprises a plurality of fluid ports adapted to connect to a heat exchanger fin for a battery cell. Each manifold segment corresponds to a battery stack comprised of a plurality cells and heat exchanger fins. At least one manifold clip is provided for securing two adjacent manifold segments together. The manifold clip bridges the coupling joint and engages retention features on each of the two manifold segments in order to inhibiting separation longitudinally between the two manifold segments. A plurality of manifold clips are configured to secure a plurality of manifold segments together accommodate a plurality of battery stack configurations.

Abstract: A fluid cooled series/parallel battery pack is provided with a fluid flow system. A plurality of prismatic battery cells are arranged in parallel in two or more rows. Fluid flows in a series flow configuration from an upstream row of batteries to a downstream row of batteries. A bypass passageway provides additional fluid flow to an inner plenum located between the rows of batteries to reduce pressure drop and provide more uniform temperatures within the rows of battery cells.

Abstract: A vented disc brake rotor is provided. In one embodiment, the rotor includes a plurality of curved directing walls disposed between first and second braking surfaces to define a plurality of flow channels. A separating wall is disposed in each flow channel to create first and second subchannels. The total cross-sectional area of each flow channel remains substantially constant over the length of the flow channel. The flow channels can be closed to the two braking surfaces. Alternatively, the braking surfaces can be intermittent, defining a plurality of gaps that provide access to the flow channels. A tapered throat region between the braking surfaces and a hat region facilitates dissipation of heat from the braking surfaces. Rotors according to the present invention can be fabricated in a single step using various conventional casting techniques, such as die-, sand- and squeeze-casting.

Abstract: A vented disc brake rotor is provided. In one embodiment, the rotor includes a plurality of curved directing walls disposed between first and second braking surfaces to define a plurality of flow channels. A separating wall is disposed in each flow channel to create first and second subchannels. The total cross-sectional area of each flow channel remains substantially constant over the length of the flow channel. The flow channels can be closed to the two braking surfaces. Alternatively, the braking surfaces can be intermittent, defining a plurality of gaps that provide access to the flow channels. A tapered throat region between the braking surfaces and a hat region facilitates dissipation of heat from the braking surfaces. Rotors according to the present invention can be fabricated in a single step using various conventional casting techniques, such as die-, sand- and squeeze-casting.

Abstract: A vented disc brake rotor is provided. In one embodiment, the rotor includes a plurality of curved directing walls disposed between first and second braking surfaces to define a plurality of flow channels. A separating wall is disposed in each flow channel to create first and second subchannels. The total cross-sectional area of each flow channel remains substantially constant over the length of the flow channel. The flow channels can be closed to the two braking surfaces. Alternatively, the braking surfaces can be intermittent, defining a plurality of gaps that provide access to the flow channels. A tapered throat region between the braking surfaces and a hat region facilitates dissipation of heat from the braking surfaces. Rotors according to the present invention can be fabricated in a single step using various conventional casting techniques, such as die-, sand- and squeeze-casting.

Abstract: A method for testing an electronic module to evaluate solder joint failures caused by thermally induced stress includes determining a thermal shock endurance test profile that represents field temperature conditions, estimating time/cycles to failure of solder joints in the module using numerical simulation techniques, selecting a design life duration for the module, comparing the design life duration of the module with the estimated time/cycles to failure of the weakest solder joint in the module, determining between robust, marginal, and non-robust module designs based on the design life duration of the module and the estimated time/cycles to failure of the at least one solder joint in the module, and determining an accelerated thermal shock endurance test specification having a test duration for testing the electronic module upon determining a marginal module design.

Abstract: Method of surface mounting an electronic component to a bonding pad on one side of a supporting insulating board carrying a planar printed circuit thereon, the pad being connected to one or more conductors on the board by use of solder material subject to one or more gas trapping through-hole vias, comprising: (a) creating at least one vent channel below the top plane of the printed circuit and extending from a location at or closely adjacent to one of said vias to a location essentially near a periphery of solder material to be placed thereover; (b) planting a deposit of solder material between the component and pad; (c) bringing the component, solder material and pad together to form an assembly; and (d) heating the assembly to momentarily reflow the solder material in place without shifting, skewing, or tilting of the component, any trapped air in said one vias being allowed to expand and migrate away through the channel to at least the periphery of the pad.