Abstract: A thermal management system for an on-vehicle battery includes a battery, a first thermal element, a second thermal element, a battery mounting bracket, and a vehicle body structural element. The battery mounting bracket includes a first portion attached to the vehicle body structural element, and a second portion attached to the first thermal element. The first thermal element is attached to the first end portion of the battery, and the second thermal element is attached to at least one of the second end portion, the first and second side portions, the top portion or the bottom portion of the battery. The first thermal element is composed from a first phase-change material having a first phase-change temperature and the second thermal element is composed from a second phase-change material having a second phase-change temperature, wherein the first phase-change temperature is greater than the second phase-change temperature.

Abstract: A thermal management system for an on-vehicle battery includes a battery, a first thermal element, a second thermal element, a battery mounting bracket, and a vehicle body structural element. The battery mounting bracket includes a first portion attached to the vehicle body structural element, and a second portion attached to the first thermal element. The first thermal element is attached to the first end portion of the battery, and the second thermal element is attached to at least one of the second end portion, the first and second side portions, the top portion or the bottom portion of the battery. The first thermal element is composed from a first phase-change material having a first phase-change temperature and the second thermal element is composed from a second phase-change material having a second phase-change temperature, wherein the first phase-change temperature is greater than the second phase-change temperature.

Abstract: A method of fabricating a fuse includes providing a fuse element within a casing. The fuse element has a plurality of ligaments configured to direct a current therethrough. A mechanical tension is then applied to the fuse element and a filler material is added to the casing so as to support the fuse element. The filler material is then solidified. Next, the mechanical tension is removed with the fuse element retaining a residual tensile stress after removal of the mechanical tension.

Abstract: Methods and systems for preventing over-temperature conditions in vehicle battery packs. In some implementations, such methods may comprise measuring a resistance within a contactor of an electric vehicle, estimating a temperature of the contactor using the measured resistance, and comparing the estimated temperature of the contactor with a threshold temperature. In some implementations, upon determining that the estimated temperature has exceeded the threshold temperature, the current delivered through the contactor may be limited.

Abstract: Methods and systems for preventing over-temperature conditions in vehicle battery packs. In some implementations, such methods may comprise measuring a resistance within a contactor of an electric vehicle, estimating a temperature of the contactor using the measured resistance, and comparing the estimated temperature of the contactor with a threshold temperature. In some implementations, upon determining that the estimated temperature has exceeded the threshold temperature, the current delivered through the contactor may be limited.

Abstract: Materials, methods, and apparatus for improving the ability of an enclosure, such as a battery enclosure, to resist leakage/ingress of water or other liquids. Some embodiments and implementations may be particularly useful in connection with vehicle battery enclosures for electric vehicles, including hybrid electric vehicles. In some implementations, a surface energy of at least a portion of a battery enclosure of an electric vehicle may be lowered by impregnating at least a portion of the battery enclosure with a lower surface energy material, coating at least a portion of the battery enclosure with a hydrophobic coating, and/or roughening a surface of at least a portion of the battery enclosure.

Abstract: A fuel cell includes a first electrically conductive plate and a first gas diffusion layer. The first gas diffusion layer is disposed over the first electrically conductive plate. Characteristically, the first gas diffusion layer comprises a first fibrous sheet having fibers coated with an electrically conductive layer. A first catalyst layer is disposed over the first gas diffusion layer and an ion conducting membrane is disposed over the first catalyst layer. The fuel cell also includes a second catalyst layer disposed over the ion conducting membrane with a second gas diffusion layer disposed over the second catalyst layer. A second electrically conductive plate is disposed over the second gas diffusion layer. Methods for forming the gas diffusion layers and the fuel cell are also provided.