Abstract: The present disclosure teaches hybrid metal/composite battery trays. The hybrid trays, which may be deep trays, may be made of a metallic (e.g., steel or aluminum alloy), cruciform-shaped partial tray with four polymer/fiber composite corner inserts that are attached to four recessed corners of the partial tray. Overlapping bond joints may be co-molded. Overlapping metallic bond surfaces may be pre-treated by laser ablation and/or by plasma treatment, to increase the bond strength between overlapping metal and polymer/fiber composite surfaces. Mechanical interlocking features may further be used to increase joint strength. An intermediate composite layer (made with short, chopped fibers) having an intermediate Coefficient of Thermal Expansion may be inserted in-between the metallic partial tray and the polymer/fiber composite corner inserts to reduce residual thermal stresses that develop during cooldown from a high temperature curing step.

Abstract: A system for measuring battery dilation. The system includes a battery cell, a magnet, and a magnetic force sensor. One of the magnet and the magnetic force sensor moves in response to expansion of the battery cell during dilation of the battery cell. The other of the magnet and the magnetic force sensor is stationary relative to the battery cell. The magnetic force sensor is configured to sense a change in magnetic force strength between the magnet and the magnetic force sensor. A control module is in communication with the magnetic force sensor. The control module is configured to measure degree of dilation of the battery cell based on the change in the magnetic force strength between the magnet and the magnetic force sensor. The magnetic force strength between the magnet and the magnetic force sensor changes as the battery cell expands during dilation.

Abstract: A battery cell includes a housing defining a battery cell space within the housing, a cathode disposed within the battery cell space, an anode disposed within the battery cell space, a reference electrode disposed within the battery cell space, and electrolyte disposed within the battery cell space and in contact with the cathode, the anode, and the reference electrode. The housing has a gas analysis port in fluid communication with the battery cell space and extending to an exterior of the housing.

Abstract: The present disclosure teaches methods of manufacturing hybrid metal/composite battery trays. The hybrid trays, which may be deep, may be made of a metallic (e.g., steel or aluminum alloy), cruciform-shaped partial tray with four, polymer/fiber composite rounded corner inserts that are attached to recessed corners of the partial tray. Overlapping bond joints may be co-molded. Overlapping metallic bond surfaces may be pre-treated by laser ablation and/or by plasma exposure, to increase the bond strength between overlapping metal and polymer/fiber composite surfaces. Mechanical interlocking features may be used to increase joint strength. Hybrid metal/composite trays may be fabricated by press-forming dissimilar parts using a molding tool and a press. Resin Transfer Molding (RTM) with thermoset resin may be used for co-molding four, fibrous preform corner inserts to the cruciform-shaped partial tray.

Abstract: A rotatable stator sensor device includes a stator support plate configured to support a steel stator having multiple teeth, a rotary table electrically isolated from the stator support plate, and at least two sensors on the rotary table. The at least two sensors are located within an inner circumference of the steel stator, each of the at least two sensors including two sensor legs, and a distance between the two sensor legs corresponds to a distance between two of the multiple teeth of the steel stator. The device includes a sensor rotation control module configured to rotate the at least two sensors between a first position aligned with a first set of the multiple teeth of the steel stator, and a second position aligned with a second set of the multiple teeth of the steel stator.

Abstract: A rotatable stator sensor device includes a stator support plate configured to support a steel stator having multiple teeth, a rotary table electrically isolated from the stator support plate, and at least two sensors on the rotary table. The at least two sensors are located within an inner circumference of the steel stator, each of the at least two sensors including two sensor legs, and a distance between the two sensor legs corresponds to a distance between two of the multiple teeth of the steel stator. The device includes a sensor rotation control module configured to rotate the at least two sensors between a first position aligned with a first set of the multiple teeth of the steel stator, and a second position aligned with a second set of the multiple teeth of the steel stator.

Abstract: A vehicle includes an apparatus for performing a method of controlling a pressure within a battery. The battery is disclosed between a support plate at a first side of the battery and a pressure plate disposed at a second side of the battery opposite the first side. The pressure plate is movable with respect to the support plate to control the pressure of the battery and including a first plate wedge. The first actuator wedge is moved parallel to the pressure plate with the first actuator wedge in contact with the first plate wedge to control a force applied by the first actuator wedge to the first plate wedge to move the pressure plate with respect to the support plate. Moving the pressure plate controls the pressure within the battery.

Abstract: A vehicle, a pressure control device and method for controlling a pressure within a battery of the vehicle. The pressure control device includes a support plate, a pressure plate and an actuator. The pressure plate is configured to move with respect to the support plate. The battery is disposed between the support plate and the pressure plate. The actuator changes between a first shape and a second shape to move the pressure plate with respect to the support plate to control the pressure within the battery.

Abstract: A battery pack having a plurality of battery modules is provided. Each of the plurality of battery modules includes a thermally conductive frame having a plurality of apertures and a plurality of battery cells, wherein each of the plurality of battery cells is disposed in one of the plurality of apertures. Each of the plurality of battery modules also includes a heating element disposed on a top of the thermally conductive frame and a cooling plate disposed on a bottom of the thermally conductive frame. The thermally conductive frame includes a plurality of cooling ribbons disposed between at least two of the plurality of apertures, wherein each of the plurality of cooling ribbons extend from top of the thermally conductive frame to the bottom of the thermally conductive frame.

Abstract: A system for measuring battery dilation. The system includes a battery cell, a magnet, and a magnetic force sensor. One of the magnet and the magnetic force sensor moves in response to expansion of the battery cell during dilation of the battery cell. The other of the magnet and the magnetic force sensor is stationary relative to the battery cell. The magnetic force sensor is configured to sense a change in magnetic force strength between the magnet and the magnetic force sensor. A control module is in communication with the magnetic force sensor. The control module is configured to measure degree of dilation of the battery cell based on the change in the magnetic force strength between the magnet and the magnetic force sensor. The magnetic force strength between the magnet and the magnetic force sensor changes as the battery cell expands during dilation.

Abstract: A mold for molding a composite preform that has an outer edge thereabout and a plurality of tethers each attached at respective opposed ends thereof to the outer edge. The mold includes first and second mold halves defining a mold body and being configured to transition between an open position and a generally closed position, and a plurality of moveable members each having a moveable gage pin configured for being wrapped thereabout by a respective one of the tethers and a respective actuator configured for moving the moveable gage pin between a respective first position in which the respective moveable gage pin is disposed at a respective first distance from a center of the mold body and a respective second position in which the respective moveable gage pin is disposed at a respective second distance from the center of the mold body that is less than the first distance.

Abstract: A vent assembly is disposed within an interior space of a vehicle for opening and closing fluid communication between the interior space and an exterior of the vehicle. The vent assembly includes a housing defining a plurality of openings and a plurality of vanes disposed in the openings. An actuator mechanism moves the vanes between an open position and a closed position, and includes a shaped memory alloy (SMA) member for actuating the vanes between the open and closed positions. The SMA member is activated when a hatch of the vehicle is opened to move the vanes into the open position and thereby open fluid communication between the interior space and the exterior to alleviate excessive air pressure buildup during closure of the hatch.

Abstract: A robotic system includes a tendon-driven end effector, a linear actuator, a flexible tendon, and a plate assembly. The linear actuator assembly has a servo motor and a drive mechanism, the latter of which translates linearly with respect to a drive axis of the servo motor in response to output torque from the servo motor. The tendon connects to the end effector and drive mechanism. The plate assembly is disposed between the linear actuator assembly and the tendon-driven end effector and includes first and second plates. The first plate has a first side that defines a boss with a center opening. The second plate defines an arcuate through-slot having tendon guide channels. The first plate defines a through passage for the tendon between the center opening and a second side of the first plate. A looped end of the flexible tendon is received within the tendon guide channels.

Abstract: A vent assembly is disposed within an interior space of a vehicle for opening and closing fluid communication between the interior space and an exterior of the vehicle. The vent assembly includes a housing defining a plurality of openings and a plurality of vanes disposed in the openings. An actuator mechanism moves the vanes between an open position and a closed position, and includes a shaped memory alloy (SMA) member for actuating the vanes between the open and closed positions. The SMA member is activated when a hatch of the vehicle is opened to move the vanes into the open position and thereby open fluid communication between the interior space and the exterior to alleviate excessive air pressure buildup during closure of the hatch.

Abstract: A vent assembly is disposed within an interior space of a vehicle for opening and closing fluid communication between the interior space and an exterior of the vehicle. The vent assembly includes a housing defining a plurality of openings and a plurality of vanes disposed in the openings. An actuator mechanism moves the vanes between an open position and a closed position, and includes a shaped memory alloy (SMA) member for actuating the vanes between the open and closed positions. The SMA member is activated when a hatch of the vehicle is open to move the vanes into the open position and thereby open fluid communication between the interior space and the exterior to alleviate excessive air pressure buildup during closure of the hatch.

Abstract: A robotic system includes a tendon-driven end effector, a linear actuator, a flexible tendon, and a plate assembly. The linear actuator assembly has a servo motor and a drive mechanism, the latter of which translates linearly with respect to a drive axis of the servo motor in response to output torque from the servo motor. The tendon connects to the end effector and drive mechanism. The plate assembly is disposed between the linear actuator assembly and the tendon-driven end effector and includes first and second plates. The first plate has a first side that defines a boss with a center opening. The second plate defines an arcuate through-slot having tendon guide channels. The first plate defines a through passage for the tendon between the center opening and a second side of the first plate. A looped end of the flexible tendon is received within the tendon guide channels.

Abstract: A transmission is configured to transfer power between an input member, first and second torque machines and an output member and includes a transmission case, a differential gear set, first and second torque transfer clutches, a first torque machine rotatably operatively couplable to a first element of the differential gear set when the second torque transfer clutch is in an applied state, and a second torque machine rotatably operatively coupled to a second element of the differential gear set. The differential gear set is configured to transfer torque between the first torque machine and the output member in a first continuously variable mode when the first torque transfer clutch is in the applied state, and to transfer torque between the first and second torque machines and the output member in a second continuously variable mode when the second torque transfer clutch is in the applied state.

Abstract: A transmission is configured to transfer power between an input member, first and second torque machines and an output member and includes a transmission case, a differential gear set, first and second torque transfer clutches, a first torque machine rotatably operatively couplable to a first element of the differential gear set when the second torque transfer clutch is in an applied state, and a second torque machine rotatably operatively coupled to a second element of the differential gear set. The differential gear set is configured to transfer torque between the first torque machine and the output member in a first continuously variable mode when the first torque transfer clutch is in the applied state, and to transfer torque between the first and second torque machines and the output member in a second continuously variable mode when the second torque transfer clutch is in the applied state.

Abstract: An electro-mechanical transmission includes a plurality of transmission components and at least one synchronizer configured to selectively engage and disengage at least two of the transmission components to effect operation in a speed range in the transmission. The synchronizer further includes a plurality of input components associated with one of the transmission components and a plurality of output components including a clutching mechanism configured to engage to at least one of the input components when the synchronizer is activated and disengage from the input component when the synchronizer is deactivated.

Abstract: A selectable one-way clutch includes a strut plate co-annular to a slide plate and a notch plate. The selectable one-way clutch is configured to transfer torque between a strut plate and a notch plate in a first direction when a displacement actuator moves a pin and a slide plate to a first position. The selectable one-way clutch is configured to disengage the strut plate from the notch plate when the displacement actuator moves the pin and the slide plate to the second position.