Abstract: An aerodynamic vehicle includes an aerodynamic heat exchanger formed as one or more body panels disposed along an outer surface of the vehicle having one or more fluidic chambers or micro-channels. The aerodynamic heat exchanger is adapted to provide effective and highly efficient heat transfer, and also to provide substantially reduced or negligible contribution to the aerodynamic drag. The aerodynamic heat exchanger may provide adequate heat rejection capacity throughout vehicle operating conditions that advantageously results in increased fuel economy and overall vehicle performance.

Abstract: A high power density battery pack for a solar-electric vehicle includes a frame with compartments for battery modules arranged therein. The modules are in thermal communication with a unitary cooling plate disposed underneath. The modules include an array of secondary cells arranged in bottom and top carriers. The bottoms of the cells are in thermal communication with a heat spreader. The cells are oriented with their electrodes in a common plane and electrically isolated by the top carrier. One or more potting materials fills the interstitial spaces between the cells. The cells are connected in parallel and series by interconnects. A module monitoring system tracks the voltage and temperature of the modules. Modules are connected in series by intra-row and inter-row interconnects. A battery management system provides a solar charging mode for both stationary and in-motion vehicle operation, and a low-power quiescent mode when the vehicle is powered down.

Abstract: A thermal management system for an electric vehicle having a drivetrain flow path coupling one or more motors and one or more inverters to an aerodynamic heat exchanger comprising one or more body panels disposed along an outer surface of the vehicle, the aerodynamic heat exchanger having one or more fluidic chambers or micro-channels. The drive flow path is decoupled from the vehicle's chiller and/or refrigeration cycle under all operating conditions. The drivetrain may be further characterized by the one or more motors being disposed proximate one or more wheels of the vehicle, such as within the wheel skirt or cowling, to capitalize on passive or free cooling via ambient airflow about the wheel. The thermal management system may further include a refrigeration cycle wherein the cabin and the battery pack are provided cooling in a parallel configuration or in a serial configuration.

Abstract: A pick-and-place assembly tool, system and method comprising a flexible array of gripper heads is adapted to pick a sheet of flexible material or a pre-assembled array of flexibly coupled elements from a flat surface and place it on a convex, doubly curved surface. Gripping action may be provided by a suction force. When picking the pre-assembled array of elements, the array of gripper heads may conform to the flat surface. The assembly tool may then be moved above and aligned to the compound curved placing surface. When lowered onto the receiving surface, the assembly tool passively may precisely conform to the convex surface. Distortion of the material or array may be controlled by flexible couplers disposed between the gripper heads. Heating elements disposed on some or all of the gripper heads may be used to tack the workpiece in place to maintain registration during subsequent processing, e.g., lamination.

Abstract: An aerodynamic vehicle includes an aerodynamic heat exchanger formed as one or more body panels disposed along an outer surface of the vehicle having one or more fluidic chambers or micro-channels. The aerodynamic heat exchanger is adapted to provide effective and highly efficient heat transfer, and also to provide substantially reduced or negligible contribution to the aerodynamic drag. The aerodynamic heat exchanger may provide adequate heat rejection capacity throughout vehicle operating conditions that advantageously results in increased fuel economy and overall vehicle performance.

Abstract: An electric vehicle having a heat exchanger formed in an aerodynamic airfoil shape comprising one or more body panels disposed along an outer surface of the vehicle having one or more fluidic chambers or micro-channels. The heat exchanger is adapted to provide effective and highly efficient heat transfer, and also to provide substantially reduced or negligible contribution to the aerodynamic drag. The heat exchanger includes a supplemental heat exchange system wherein at least a portion of the heat exchange capacity is provided by an inner heat exchange surface of the heat exchanger exposed to an interstitial space within the vehicle. Airflow is forced, via a fan for example, from an aerodynamically-efficient inlet, over the inner heat exchange surface, and exhausted through an aerodynamically-efficient outlet, thereby providing a supplemental heat exchange system including substantially reduced or negligible contribution to the aerodynamic drag.

Abstract: A dual trailing link, rear wheel suspension system for a vehicle is described. The trailing links have proximal ends coupled to the vehicle chassis and distal ends coupled to a bracket with a knuckle for the wheel. The distal ends have a larger distance between them than the proximal ends, allowing for an improved instantaneous center, which may be useful for determining lift/squat characteristics. The distal ends may be disposed proximate the knuckle, thereby providing the largest possible knuckle pivot radius, i.e., effective swingarm length, for a predetermined chassis-wheel distance, which provides a smoother, more comfortable riding experience. The disclosed arrangement makes maximum use of the space allotted for the rear suspension system and is suitable for use with an aerodynamic cowling for an energy efficient vehicle.

Abstract: The present invention relates to an airside system for a vehicle HVAC system and to a HVAC apparatus, system and method having a multidirectional vent formed integrally with a mount adapted to receive a user interface in the form of a centrally disposed touch screen. The vent/interface assembly may be disposed inside the vehicle cabin including, but not limited to, the dashboard and/or instrument panel. The one or more outlets of the vent may be disposed partially or completely around the touch screen perimeter. Each outlet may flow in one or more directions, be individually adjustable either automatically or manually, or be stationary. The assembly may be configured to position the user interface offset from the dashboard. The outlet(s) of the vent may be partially or completely hidden behind the user interface. On/off and directional control of each outlet may be achieved by means of vanes, blades, and/or slots.

Abstract: The invention relates to an apparatus, system and method for a doubly curved panel with a light emitting element, such as for a body panel of an automobile. Also described is a doubly curved solar panel with doubly curved solar cells and a light emitting element. The light emitting element may be of the LED or electroluminescent type and be embedded in the solar panel while remaining electrically decoupled from the solar array. The solar panel comprises doubly-curved substrate and superstrate preforms and at least one rigid layer. The preforms may comprise one or more strengthened glass and/or polymer layers. Polymer preforms may be formed by flat lamination followed by thermoforming. A core comprising lower and upper encapsulant layers sandwiching the light emitting element and solar cell array is disposed between substrate and superstrate preforms forming a lamination stack which is then subjected to a lamination process.

Abstract: A solar module for industrial applications is disclosed that includes a solar panel coupled to a damper. The damper provides support against static and dynamic loads with reduced risk of damage to the solar cells in applications such as architectural, marine, aeronautical, terrestrial and/or other structural panels, and to reduce noise, vibration and harshness for industrial utility. The solar panel electrical terminations may be housed in one or more junction boxes formed from flexible material of the damper, and having simplified electrical connections with strain relief. The solar module with integrated solar panel, damper and junction boxes constitutes a lightweight, durable body panel with a reduced number of components that may be manufactured in high volume and at low cost.

Abstract: The invention relates to improved methods and implementation of reliably manufacturing laminated solar panel products having one or more axis of curvature, wherein at least one solar cell also has one or more axis of curvature, in a manufacturing plant, the manufacturing plant being capable of continuous, optimized operation. A substrate and a superstrate having a doubly-curved geometry may be assembled with a core disposed therebetween, the core comprising a solar cell array including at least one solar cell. During the lamination process, the plant substantially eliminates cracking of the at least one solar cell of the solar array through controlled and uniform application of lamination pressure and temperature that applies uniform local pressure simultaneously to each cell, resulting in a durable and reliable product. The invention further relates to a plant and/or facility having efficient, effective, and repeatable results relating to such methods.

Abstract: An apparatus, system, and method is disclosed, which integrates a flexible solar module with a freestanding, molded panel assembly in a curved geometry, such as for a vehicle dashboard, using insert molding. A flexible solar module with surface texture may be integrated with a larger body panel with a seamless, flush surface and uninterrupted texture. A flexible module may be adhered to a textured cap sheet and overmolded on a back side. A smooth, flexible module may be over-molded on a front or back side, in a single molding operation. A smooth, flexible module may be overmolded on front and back sides using two molding operations. Methods of flexible and rigid module retention within the insert mold are disclosed. Methods of surface texturing are also described. Furthermore, methods of concealing the solar cells through color matching are disclosed.

Abstract: A LIN communication system may include a gateway module coupled to one or more LIN strings, each LIN string including one or more hardware-only point-of-use controllers (PoUC) and/or one or more programmable point-of-use controllers (PoUC). Each PoUC may be tailored to a plurality of end devices, and centrally-disposed with respect to the same. The system represents an optimized arrangement that minimizes weight, cost, and complexity of the system, while providing optimized functionality in terms of processing power, bandwidth, and the like, to achieve only that which is needed to control the vehicle. The system employs a scheduler that may interleave I/O and diagnostic messages on the LIN-protocol bus at the PoUC level that may reduce unused bandwidth. This system may be particularly adapted for use in an electric vehicle having on-board solar panels, wherein the weight of system components is a dominating factor in the vehicle design.

Abstract: An aerodynamic vehicle includes an aerodynamic heat exchanger formed as one or more body panels disposed along an outer surface of the vehicle having one or more fluidic chambers or micro-channels. The aerodynamic heat exchanger is adapted to provide effective and highly efficient heat transfer, and also to provide substantially reduced or negligible contribution to the aerodynamic drag. The aerodynamic heat exchanger may provide adequate heat rejection capacity throughout vehicle operating conditions that advantageously results in increased fuel economy and overall vehicle performance.

Abstract: The invention relates to an apparatus, system and method for a two-axis of curvature solar panel with doubly-curved solar cells. The solar panel comprises substrate and superstrate preforms having two-axis of curvature geometry and at least one rigid layer. The preforms may comprise one or more strengthened glass and/or polymer layers. A core comprising lower and upper encapsulant layers sandwiching a solar cell array is disposed between substrate and superstrate preforms forming a lamination stack. The solar cells may be tacked to the lower encapsulant layer. The preforms may be formed by flat lamination followed by thermoforming. The curved solar panel may comprise a flange suitable for assisting the assembly process and be made of materials with disparate mechanical and thermal properties. A method is provided wherein preforms and core layers are assembled and laminated, and post-processing that may include trimming and edge sealing.

Abstract: The invention relates to improved methods and implementation of reliably manufacturing laminated solar panel products having one or more axis of curvature, wherein at least one solar cell also has one or more axis of curvature, in a manufacturing plant, the manufacturing plant being capable of continuous, optimized operation. A substrate and a superstrate having a doubly-curved geometry may be assembled with a core disposed therebetween, the core comprising a solar cell array including at least one solar cell. During the lamination process, the plant substantially eliminates cracking of the at least one solar cell of the solar array through controlled and uniform application of lamination pressure and temperature that applies uniform local pressure simultaneously to each cell, resulting in a durable and reliable product. The invention further relates to a plant and/or facility having efficient, effective, and repeatable results relating to such methods.

Abstract: An adhesively bonded dashboard including a solar module, and methods of manufacture pertaining thereto, are provided. The dashboard may be decorative in terms of an aesthetically pleasing texture and/or color. The solar cells contained therein may be curved along one axis of curvature to form one or more desirable shapes.

Abstract: Radiators, automobiles, and methods of transferring thermal energy to or from an automobile. The radiators include elongated, flattened tubes that transfer thermal energy while minimally affecting the reference area of the automobile, reducing the amount of drag produced by the radiator.

Abstract: Vehicles having a plurality of solar cells arranged on a dashboard of the vehicle. The solar cells are arranged at an acute angle relative to a longitudinal axis of the dashboard, and may have an arcuate shape along the longitudinal axis of the dashboard. The solar cells may have an irregular octagon shape and may be more flexible along one axis of symmetry relative to the other axis of symmetry.