Patents by Inventor Evan J. Dawley

Evan J. Dawley has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Publication number: 20220263207
    Abstract: Presented are finger-proof electrical terminals for battery assemblies, methods for making/using such electrical terminals, and vehicles with battery modules having finger-proof electrical terminals for bolted busbar connections. A battery assembly includes one or more electrochemical battery cells and one or more electrical terminals each electrically connected to the battery cell(s) and having a contact face to electrically connect the battery assembly to an electrical connector. A threaded nut attaches each electrical terminal to one of the electrical connectors. An electrically insulating nut cap is attached to each threaded nut. A battery housing, which stores therein the battery cell(s), includes an electrically insulating housing wall with one or more terminal jackets each mounting therein one of the electrical terminals.
    Type: Application
    Filed: February 12, 2021
    Publication date: August 18, 2022
    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: Evan J. Dawley, Phillip D. Hamelin, Scott W. Vaubel, Andrew P. Oury, Neil A. Patel
  • Patent number: 11205810
    Abstract: A thermal interfacing assembly for use in a power module having at least one battery module and a cooling plate, and corresponding method of forming the thermal interfacing assembly. The thermal interfacing material is deposited over a first surface of the cooling plate such that the thermal interfacing material conforms to the shape of the first surface. The thermal interfacing material is configured to be electrically insulating and thermally conductive. A first embedded heater is positioned adjacent to the thermal interfacing material. The first embedded heater includes an electrically-conductive portion and a resistive portion. The battery module is installed adjacent to the first embedded heater such that the first embedded heater is directly in contact with a first face of the battery module. The first embedded heater is employed to at least partially induce in-place curing of the thermal interfacing material.
    Type: Grant
    Filed: June 3, 2019
    Date of Patent: December 21, 2021
    Assignee: GM Global Technology Operations LLC
    Inventors: Evan J. Dawley, Mahmoud Abd Elhamid
  • Patent number: 11171391
    Abstract: Assemblies and methods are provided for manufacturing a battery. A number of cells each have tabs for coupling the cell in the battery assembly. A housing has an opening through which each tab extends. The tabs are folded to overlie an outer surface of the housing. A bus bar is disposed on an opposite side of the tabs from the housing, with a coupling joint between the bus bar and the cells. The coupling joint may comprise a weld.
    Type: Grant
    Filed: September 9, 2019
    Date of Patent: November 9, 2021
    Assignee: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: Evan J. Dawley, Hongliang Wang
  • Patent number: 11058013
    Abstract: A method of manufacturing an interconnect board (ICB) assembly for a battery module, the ICB assembly having a printed circuit board assembly (PCBA) and a carrier frame, includes depositing solder paste onto a printed circuit board (PCB) and/or a flexible printed circuit (flex circuit). The flex circuit has a conductive foil substrate coated with insulating material, and defines tabular flying leads radially-projecting from the flex circuit's periphery. The method may include positioning the PCB adjacent to the flex circuit such that the PCB and flex circuit are in direct contact along a flex interface surface of the PCB, and integrally joining the PCB and flex circuit along the interface surface to form the PCBA. The PCBA connects to the carrier frame to construct the ICB assembly. The battery module may be manufactured by connecting the ICB assembly to battery cells of the battery module.
    Type: Grant
    Filed: February 26, 2019
    Date of Patent: July 6, 2021
    Assignee: GM Global Technology Operations LLC
    Inventor: Evan J. Dawley
  • Patent number: 11038192
    Abstract: Configurations for a power module having a flexible circuit assembly and corresponding method. The flexible circuit assembly has at least one electrically conductive portion. A first plurality of cells is placed adjacent to one another to form a first cell layer, the first cell layer being positioned on a first side of the flexible circuit assembly. Each of the first plurality of cells has a respective cell body with at least four respective edges. The first plurality of cells has respective cell tabs, including a respective first tab and a respective second tab both extending from one of the at least four respective edges. The flexible circuit assembly is configured to be aligned with the first cell layer such that a voltage sensing circuit joint is concurrently completed when the respective cell tabs of the first cell layer are joined to respective captured portions of the flexible circuit assembly.
    Type: Grant
    Filed: June 3, 2019
    Date of Patent: June 15, 2021
    Assignee: GM Global Technology Operations LLC
    Inventor: Evan J. Dawley
  • Patent number: 11018381
    Abstract: An interconnect board (ICB) assembly is used with a battery module and a battery controller. The ICB assembly includes a printed circuit board assembly (PCBA) integrally formed from a printed circuit board (PCB) and a flex circuit. The PCB has a component surface populated with electronic components which measure and report parameters of the battery module to the battery controller. The flex circuit is constructed of conductive foil, and defines tabular flying leads that project from a periphery of the flex circuit. A window may be present in the flex circuit. A carrier frame has a support surface flanked by busbars. The PCBA is seated on the support surface, with the flying leads conductively joined to a corresponding busbar. A battery system includes the battery controller and the ICB assembly.
    Type: Grant
    Filed: February 26, 2019
    Date of Patent: May 25, 2021
    Assignee: GM Global Technology Operations LLC
    Inventor: Evan J. Dawley
  • Patent number: 11011803
    Abstract: A connection assembly includes a busbar defining a first hole, and a circuit board defining a second hole that aligns with the first hole. A battery pack assembly includes the connection assembly. The connection assembly includes a pin having a first body portion and a second body portion. The first body portion is disposed in the first hole and the second body portion is disposed in the second hole. The first body portion defines a first eyelet to allow the first body portion to flex as the first body portion engages the busbar inside the first hole. The second body portion defines a second eyelet to allow the second body portion to flex as the second body portion engages the circuit board inside the second hole. A method of assembling the battery pack assembly includes a first material molded to the busbar to form a frame attached to the busbar.
    Type: Grant
    Filed: April 29, 2019
    Date of Patent: May 18, 2021
    Assignee: GM Global Technology Operations LLC
    Inventor: Evan J. Dawley
  • Patent number: 10991998
    Abstract: A thermal interface member may comprise a substrate having a first surface and an opposite second surface, an electrically conductive layer disposed on the first surface of the substrate, and an electrically resistive layer disposed on the first surface of the substrate. The substrate may comprise a compliant electrically insulating and thermally conductive material including a polymeric matrix phase and a dispersed phase of thermally conductive particles. The conductive layer may be patterned into a first electrode and a second electrode spaced apart from the first electrode on the first surface of the substrate. The resistive layer may be in electrical contact with the first and second electrodes of the conductive layer and may comprise a resistive material having a positive resistance temperature coefficient and a resistance that increases with an increase in temperature.
    Type: Grant
    Filed: January 28, 2019
    Date of Patent: April 27, 2021
    Assignee: GM Global Technology Operations LLC
    Inventors: Evan J. Dawley, Herman K. Phlegm, Mahmoud Abd Elhamid, Chih-Cheng Hsu, Timothy J. Fuller
  • Publication number: 20210074985
    Abstract: Assemblies and methods are provided for manufacturing a battery. A number of cells each have tabs for coupling the cell in the battery assembly. A housing has an opening through which each tab extends. The tabs are folded to overlie an outer surface of the housing. A bus bar is disposed on an opposite side of the tabs from the housing, with a coupling joint between the bus bar and the cells. The coupling joint may comprise a weld.
    Type: Application
    Filed: September 9, 2019
    Publication date: March 11, 2021
    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: Evan J. Dawley, Hongliang Wang
  • Publication number: 20200403197
    Abstract: A battery module includes a housing and multiple battery cells. The housing may have a positive battery module terminal and a negative battery module terminal. The battery cells may be mounted in the housing. Each battery cell may have a positive battery cell terminal and a negative battery cell terminal disposed on opposing battery cell ends. The positive battery cell terminal and the negative battery cell terminal of each battery cell may be offset from a plane perpendicular to the opposing battery cell ends and passing through a center of the battery cell. The battery cells may be arranged as multiple groups with a common side. The positive and negative battery cell terminals on the common side may alternate about the plane in every other group. The groups may be electrically connected in series between the positive battery module terminal and the negative battery module terminal.
    Type: Application
    Filed: June 18, 2019
    Publication date: December 24, 2020
    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventor: Evan J. Dawley
  • Publication number: 20200388798
    Abstract: A lithium ion battery pouch cell is disclosed that includes a copper-free negative terminal tab in which at least a joining region of an exterior portion of the negative terminal tab is aluminum or nickel-coated aluminum. In this way, the negative terminal tab of the lithium ion battery pouch cell may be welded to a common aluminum bus bar along with a positive terminal tab of another lithium ion battery pouch cell, or the negative terminal tab and the positive terminal tab of the two lithium ion battery pouch cells may be directly welded together in the absence of a common bus bar. Because the negative terminal tab does not include copper, the difficulties inherent in welding aluminum and copper, such as the formation of brittle Al—Cu intermetallic compounds, can be avoided. Lithium ion battery packs that include the disclosed lithium ion battery pouch cell are also disclosed.
    Type: Application
    Filed: June 4, 2019
    Publication date: December 10, 2020
    Inventors: Hongliang Wang, James G. Schroth, Fang Dai, Evan J. Dawley
  • Publication number: 20200388874
    Abstract: A thin, conformable electrochemical device according to various aspects of the present disclosure includes an electrically-insulating housing, a plurality of current collectors, a plurality of electrochemical cells, and positive and terminals. The housing includes first and second film portions that cooperate to at least partially define an interior region. The current collector and electrochemical cells are disposed within the interior region. The electrochemical cells are electrically connected to one another via the current collectors. The plurality of electrochemical cells includes a first electrochemical cell and a second electrochemical cell. Each electrochemical cell includes a positive electrode, a negative electrode, and a separator. The positive and negative terminals are electrically connected to the electrochemical cells.
    Type: Application
    Filed: June 7, 2019
    Publication date: December 10, 2020
    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: Evan J. DAWLEY, Mahmoud ABD ELHAMID
  • Publication number: 20200358051
    Abstract: A battery pack assembly includes a battery cell and a first plate. A body of the battery cell includes a first tab and a second tab. The first plate includes a first edge and a second edge opposing each other. The first plate defines a slot having a first portion and a second portion adjoining with each other. The first portion of the slot is defined through the first edge of the first plate such that the slot is open at the first edge. The first portion of the slot tapers toward the second portion. The first tab is disposed in the first portion of the slot at the first edge in an initial position. The first tab is disposed in the second portion of the slot in a final position to couple the battery cell and the first plate together.
    Type: Application
    Filed: May 7, 2019
    Publication date: November 12, 2020
    Applicant: GM Global Technology Operations LLC
    Inventor: Evan J. Dawley
  • Publication number: 20200343513
    Abstract: A connection assembly includes a busbar defining a first hole, and a circuit board defining a second hole that aligns with the first hole. A battery pack assembly includes the connection assembly. The connection assembly includes a pin having a first body portion and a second body portion. The first body portion is disposed in the first hole and the second body portion is disposed in the second hole. The first body portion defines a first eyelet to allow the first body portion to flex as the first body portion engages the busbar inside the first hole. The second body portion defines a second eyelet to allow the second body portion to flex as the second body portion engages the circuit board inside the second hole. A method of assembling the battery pack assembly includes a first material molded to the busbar to form a frame attached to the busbar.
    Type: Application
    Filed: April 29, 2019
    Publication date: October 29, 2020
    Applicant: GM Global Technology Operations LLC
    Inventor: Evan J. Dawley
  • Publication number: 20200275555
    Abstract: A method of manufacturing an interconnect board (ICB) assembly for a battery module, the ICB assembly having a printed circuit board assembly (PCBA) and a carrier frame, includes depositing solder paste onto a printed circuit board (PCB) and/or a flexible printed circuit (flex circuit). The flex circuit has a conductive foil substrate coated with insulating material, and defines tabular flying leads radially-projecting from the flex circuit's periphery. The method may include positioning the PCB adjacent to the flex circuit such that the PCB and flex circuit are in direct contact along a flex interface surface of the PCB, and integrally joining the PCB and flex circuit along the interface surface to form the PCBA. The PCBA connects to the carrier frame to construct the ICB assembly. The battery module may be manufactured by connecting the ICB assembly to battery cells of the battery module.
    Type: Application
    Filed: February 26, 2019
    Publication date: August 27, 2020
    Applicant: GM Global Technology Operations LLC
    Inventor: Evan J. Dawley
  • Publication number: 20200274204
    Abstract: An interconnect board (ICB) assembly is used with a battery module and a battery controller. The ICB assembly includes a printed circuit board assembly (PCBA) integrally formed from a printed circuit board (PCB) and a flex circuit. The PCB has a component surface populated with electronic components which measure and report parameters of the battery module to the battery controller. The flex circuit is constructed of conductive foil, and defines tabular flying leads that project from a periphery of the flex circuit. A window may be present in the flex circuit. A carrier frame has a support surface flanked by busbars. The PCBA is seated on the support surface, with the flying leads conductively joined to a corresponding busbar. A battery system includes the battery controller and the ICB assembly.
    Type: Application
    Filed: February 26, 2019
    Publication date: August 27, 2020
    Applicant: GM Global Technology Operations LLC
    Inventor: Evan J. Dawley
  • Publication number: 20200243926
    Abstract: A thermal interface member may comprise a substrate having a first surface and an opposite second surface, an electrically conductive layer disposed on the first surface of the substrate, and an electrically resistive layer disposed on the first surface of the substrate. The substrate may comprise a compliant electrically insulating and thermally conductive material including a polymeric matrix phase and a dispersed phase of thermally conductive particles. The conductive layer may be patterned into a first electrode and a second electrode spaced apart from the first electrode on the first surface of the substrate. The resistive layer may be in electrical contact with the first and second electrodes of the conductive layer and may comprise a resistive material having a positive resistance temperature coefficient and a resistance that increases with an increase in temperature.
    Type: Application
    Filed: January 28, 2019
    Publication date: July 30, 2020
    Inventors: Evan J. Dawley, Herman K. Phlegm, Mahmoud Abd Elhamid, Chih-Cheng Hsu, Timothy J. Fuller
  • Publication number: 20200243927
    Abstract: A thermal interfacing assembly for use in a power module having at least one battery module and a cooling plate, and corresponding method of forming the thermal interfacing assembly. The thermal interfacing material is deposited over a first surface of the cooling plate such that the thermal interfacing material conforms to the shape of the first surface. The thermal interfacing material is configured to be electrically insulating and thermally conductive. A first embedded heater is positioned adjacent to the thermal interfacing material. The first embedded heater includes an electrically-conductive portion and a resistive portion. The battery module is installed adjacent to the first embedded heater such that the first embedded heater is directly in contact with a first face of the battery module. The first embedded heater is employed to at least partially induce in-place curing of the thermal interfacing material.
    Type: Application
    Filed: June 3, 2019
    Publication date: July 30, 2020
    Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
    Inventors: Evan J. Dawley, Mahmoud Abd Elhamid
  • Patent number: 10680226
    Abstract: A battery assembly includes a battery cell, conductive bus bar, and printed circuit board assembly (PCBA). A cell tab of the battery assembly has a first portion extending from a perimeter edge of a pouch and a second portion arranged orthogonally with respect to the first portion. The bus bar defines a tab slot through which the first portion extends, and has a major surface adjacent to the second portion. The PCBA defines an elongated welding window orthogonal to a longitudinal axis of the PCBA. The PCBA is mounted over the bus bar such that surface area of the second portion is exposed through the welding window, and in turn is welded to the bus bar through and within the welding window. A spring element may be positioned between the carrier frame and the PCBA. A method of making the battery assembly is also provided.
    Type: Grant
    Filed: May 15, 2018
    Date of Patent: June 9, 2020
    Assignee: GM Global Technology Operations LLC
    Inventor: Evan J. Dawley
  • Patent number: 10629915
    Abstract: A battery cell has positive and negative cell tabs protruding from a first edge and a cell stack-up within a pouch. Anode and cathode foils are connected to the cell tabs proximate the first edge, with the anode foils connected to each other proximate a second edge. An outermost current collector of the anode foils exists with respect to a thickness of the cell stack-up. The cathode foils are connected to the positive cell tab proximate the first edge. The anode foils are connected to each other and the negative cell tab proximate the second edge, such that the outermost current collector forms an internal bus bar between the first and second edges. The battery cell has asymmetrical packaging and symmetrical internal current paths. A system includes a battery pack driving a load, with the battery pack having battery cells constructed as set forth above.
    Type: Grant
    Filed: April 6, 2018
    Date of Patent: April 21, 2020
    Assignee: GM Global Technology Operations LLC
    Inventors: Evan J. Dawley, Sherman H. Zeng