Abstract: An automotive battery pack enclosure, assembly and method of housing battery pack cells within an enclosure. The enclosure includes a tray that defines a mounting surface for the various individual battery cells, as well as an upstanding wall, while the assembly further includes numerous individual battery cells aligned along a stacking axis within the enclosure. The wall is made from a continuous extruded preform with periodically-spaced miters that permit bending such that the wall can assume any shape defined by the various panels. The panels cooperative with the peripheral edges of the tray to define a battery container with a footprint shape generally similar to that of the tray. By being formed from a substantially one-piece preform, all of the corners—save the one formed where wall ends are brought into adjacent cooperation with one another—define a continuous structural seal without the need for sealants, welds or other supplemental closure approaches.

Abstract: Provided herein is a heat exchange assembly for conducting air flow through an air cooled vehicle battery, including: a housing enclosing a battery pack having a plurality of cells; and a manifold operably connected to the housing, wherein the manifold includes an inlet for receiving air flow into the battery pack and an outlet for exhausting air flow out of the battery pack, wherein the inlet and the outlet form a single heat exchange duct that passes through a single opening on a face of the housing. Also provided herein is a vehicle incorporating the disclosed heat exchange assembly and a method of conducting air flow through an air cooled battery in a vehicle.

Abstract: An automotive battery pack enclosure, assembly and method of housing battery pack cells within an enclosure. The enclosure includes a tray that defines a mounting surface for the various individual battery cells, as well as an upstanding wall, while the assembly further includes numerous individual battery cells aligned along a stacking axis within the enclosure. The wall is made from a continuous extruded preform with periodically-spaced miters that permit bending such that the wall can assume any shape defined by the various panels. The panels cooperative with the peripheral edges of the tray to define a battery container with a footprint shape generally similar to that of the tray. By being formed from a substantially one-piece preform, all of the corners—save the one formed where wall ends are brought into adjacent cooperation with one another—define a continuous structural seal without the need for sealants, welds or other supplemental closure approaches.

Abstract: A framed lithium battery cell group includes a first frame member (20) and a second frame member (30). The frame members are locked together, clamping the lithium battery cell pack (10) on the seal edge surfaces (13, 16), thereby providing structural rigidity and protection from damage due to handling and vibration. Each of the frame members (20, 30) has multiple pins (25) and sockets (26) on the side opposite the clamping surface (33) to facilitate aligning and stacking multiple lithium battery cell pack and frame assemblies to form a lithium battery cell group (50). Each of the frame members (20, 30) include a buss bar capture feature (22, 32) having a bus bar (40) inserted therein for electrically connecting all of the terminals for a given lithium battery pack group to the buss bar (40).

Abstract: Provided herein is a heat exchange assembly for conducting air flow through an air cooled vehicle battery, including: a housing enclosing a battery pack having a plurality of cells; and a manifold operably connected to the housing, wherein the manifold includes an inlet for receiving air flow into the battery pack and an outlet for exhausting air flow out of the battery pack, wherein the inlet and the outlet form a single heat exchange duct that passes through a single opening on a face of the housing. Also provided herein is a vehicle incorporating the disclosed heat exchange assembly and a method of conducting air flow through an air cooled battery in a vehicle.

Abstract: A system for operating a hybrid vehicle that includes a chargeable energy storage device, a single dynamo (motor/generator combination) an internal combustion engine, and a torque coupling device configured to variably couple the engine to the dynamo. The torque coupling device is such that using only a single dynamo, the system is able to operate in different modes expected of hybrid vehicles, such as: electric drive only, engine drive only, electric and engine drive combined, and charging of the chargeable energy storage device.

Abstract: A battery safety system that includes a battery terminal configured for making an electrical connection to the system, an electrical disconnect operable to a disconnected state whereby a battery voltage is electrically isolated from the battery terminal, and a connected state, whereby the battery voltage is electrically coupled to the battery terminal. The battery safety system also includes and a terminal guard movable to an exposed position effective to allow making the electrical connection to the battery terminal, and a protected position effective to prevent electrical contact with the battery terminal other than via the electrical connection. The system is configured to prevent the electrical disconnect from being operated to the connected state if the terminal guard is not at the protected position.

Abstract: A battery suitable for hybrid vehicle use that includes coolant flow channels overlying a surface of each battery cell forming the battery, and a plenum that provides structural integrity to the battery. The plenum also defines an intake plenum having an intake cross section area that decreases as a distance from an intake opening increases and an exhaust plenum having an exhaust cross section area that increases as a distance from an exhaust opening decreases. The arrangement of battery cells and the plenum provide for a scalable battery design that can be readily adapted to various battery power ratings and cooling capabilities such as forced air cooling.

Abstract: A system for operating a hybrid vehicle that includes a chargeable energy storage device, a single dynamo (motor/generator combination) an internal combustion engine, and a torque coupling device configured to variably couple the engine to the dynamo. The torque coupling device is such that using only a single dynamo, the system is able to operate in different modes expected of hybrid vehicles, such as: electric drive only, engine drive only, electric and engine drive combined, and charging of the chargeable energy storage device.

Abstract: A battery safety system that includes a battery terminal configured for making an electrical connection to the system, an electrical disconnect operable to a disconnected state whereby a battery voltage is electrically isolated from the battery terminal, and a connected state, whereby the battery voltage is electrically coupled to the battery terminal. The battery safety system also includes and a terminal guard movable to an exposed position effective to allow making the electrical connection to the battery terminal, and a protected position effective to prevent electrical contact with the battery terminal other than via the electrical connection. The system is configured to prevent the electrical disconnect from being operated to the connected state if the terminal guard is not at the protected position.

Abstract: A lithium battery includes a lithium cell package disposed within an enclosure having means to route gases vented from the package in a controlled fashion. A plurality of enclosures may be stacked, defining a vent conduit for collecting and routing gases vented from any of the plurality of enclosures. Means for interfacing a gas conveyance means to the vent conduit are provided. In a further aspect, the enclosure may include features to control the location in the cell package at which vented gases are released.

Abstract: A prismatic-cell battery pack is provided with integral coolant passages including an intake plenum, an exhaust plenum, and a distributed array of coolant channels coupled between the intake plenum and the exhaust plenum. Coolant medium forced into the intake plenum enters the coolant channels in parallel, draws heat away from the battery cells, and then enters the exhaust plenum for expulsion into the atmosphere. The battery pack is configured as a set of stackable interlocking battery cell modules including at least one battery cell in thermal proximity to an array of coolant channels distributed over the profile of the battery cell, and a pair of peripheral chambers joined to opposite ends of the coolant channels to form the intake and exhaust plenums when the modules are arranged and interlocked in a lineal stack.

Abstract: A prismatic-cell battery pack is provided with integral coolant passages and a distributed array of coolant channels coupled between an intake plenum and a pair of exhaust plenums. Coolant medium forced into the intake plenum draws heat away from the battery cells, and then exits via the exhaust plenum for expulsion of heat into the atmosphere. The battery pack is configured as a set of stackable interlocking battery cell modules including at least one battery cell in thermal proximity to an array of coolant channels distributed over the profile of the battery cell, and a pair of peripheral chambers joined to opposite ends of the coolant channels to form the intake and exhaust plenums when the modules are arranged and interlocked in a lineal stack. The entry end of each channel is closer to a centerline of the battery cell than the exit end of the channel.

Abstract: A process for physically bonding two parts to each other is disclosed. In addition, a process for forming electrical connections have a low resistance is disclosed. The process is generally applicable to the joining of two parts each formed from a metal, an alloy, or a combination thereof. The process finds special use in the formation of multi-celled batteries. The process involves placing two parts or electrical conductors in contact with each other and then bonding them to each other using a kinetic spray process and powder particles. In formation of a multi-celled battery the particles are preferably electrically conductive. The process enables for rapid and cost effective formation of a physical connection. In addition, the connection can have an electrical resistance of less than about 0.5 milli Ohms and strength equal or greater than ultrasonic welding.

Abstract: A pressure connection apparatus includes a conductive spring member having first and second end portions that are curved, and first and second retaining members having curved pockets that are oppositely oriented for receiving the first and second curved ends of the conductive spring member. An aluminum foil terminal of one battery is sandwiched between the conductive spring and the pocket of the first retaining member, while a copper foil terminal of another battery is sandwiched between the conductive spring and the pocket of the second retaining member. The spring member is clad with aluminum on one side and copper on the other, and the end portions are oppositely curved so that the aluminum-clad side contacts the aluminum foil terminal within the pocket of the first retaining member, and the copper-clad side contacts the copper foil terminal within the pocket of the second retaining member.

Abstract: A prismatic-cell battery pack is provided with integral coolant passages including an intake plenum, an exhaust plenum, and a distributed array of coolant channels coupled between the intake plenum and the exhaust plenum. Coolant medium forced into the intake plenum enters the coolant channels in parallel, draws heat away from the battery cells, and then enters the exhaust plenum for expulsion into the atmosphere. The battery pack is configured as a set of stackable interlocking battery cell modules including at least one battery cell in thermal proximity to an array of coolant channels distributed over the profile of the battery cell, and a pair of peripheral chambers joined to opposite ends of the coolant channels to form the intake and exhaust plenums when the modules are arranged and interlocked in a lineal stack.

Abstract: A pressure connection apparatus includes a conductive spring member having first and second end portions that are curved, and first and second retaining members having curved pockets that are oppositely oriented for receiving the first and second curved ends of the conductive spring member. An aluminum foil terminal of one battery is sandwiched between the conductive spring and the pocket of the first retaining member, while a copper foil terminal of another battery is sandwiched between the conductive spring and the pocket of the second retaining member. The spring member is clad with aluminum on one side and copper on the other, and the end portions are oppositely curved so that the aluminum-clad side contacts the aluminum foil terminal within the pocket of the first retaining member, and the copper-clad side contacts the copper foil terminal within the pocket of the second retaining member.

Abstract: True Top Dead Center (TDC) of an engine piston is determined through determination of the Location of Peak Pressure (LPP) using either of two simplified algorithms. A Heat Loss Offset (HLO), drawn from a look-up table based on engine speed, molar mass of the air being compressed, and heat loss rate to the cylinder walls, is added to the calculated LPP to provide a corrected and true TDC position for each piston, which corrects for errors in target wheel tooth location of a camshaft position sensor and for any misalignment in the target wheel during installation on an engine. Preferably, such a calculation is carried out for each cylinder of a multi-cylinder engine during operation thereof, thus further correcting for machining errors in the crankshaft and for crankshaft bending during the life of the engine. The invention thus allows for more accurate combustion calculations for each individual cylinder.

Abstract: True Top Dead Center (TDC) of an engine piston is determined through determination of the Location of Peak Pressure (LPP) using either of two simplified algorithms. A Heat Loss Offset (HLO), drawn from a look-up table based on engine speed, molar mass of the air being compressed, and heat loss rate to the cylinder walls, is added to the calculated LPP to provide a corrected and true TDC position for each piston, which corrects for errors in target wheel tooth location of a camshaft position sensor and for any misalignment in the target wheel during installation on an engine. Preferably, such a calculation is carried out for each cylinder of a multi-cylinder engine during operation thereof, thus further correcting for machining errors in the crankshaft and for crankshaft bending during the life of the engine. The invention thus allows for more accurate combustion calculations for each individual cylinder.

Abstract: A battery assembly is designed to include a plurality of cells positioned parallel to each other. A frame including end supports position the cells appropriately. Each of the cells includes a first terminal and a second terminal. Two buses are positioned over all of the first terminals and all of the second terminals. Each of the buses includes slots allowing the terminals to extend therethrough. Once through, the terminals are bent over the bus bar. A slide is then positioned over the terminals protecting the terminals and maintaining the terminals in electrical contact with each other. This battery assembly allows more than three cells to be connected to each other and is versatile enough to allow the removal of certain cells to enhance the airflow through the battery assembly.