Abstract: A battery pack with a drain plug and a circuit to detect when a liquid coolant has entered the battery pack. A soluble plug may be disposed within the cavity of the carrier; the soluble plug is configured to at least partially dissolve when fluidly coupled with a coolant allowing a portion of the coolant to flow between the inlet and the outlet and out of the battery pack. A strain gauge cooperative with the carrier such that a measured resistance change in the strain gauge corresponds to the soluble plug in contact with the liquid coolant. An associated circuit with the drain plug provides notification of the activation of the drain plug to the on-board computer systems.

Abstract: Fuel cell bipolar plates are made by depositing a pinhole free corrosion resistant and/or a conductive layer on a metal plate using an atomic layer deposition method. In one embodiment, a conductive layer is deposited on an anodized metal plate using atomic layer deposition method. In another embodiment, at least one corrosion resistant metal oxide layer and at least one conductive layer are deposited on a metal plate individually using atomic layer deposition method. In yet another embodiment, a corrosion resistant and conductive metal oxynitride layer is deposited on a metal plate using an atomic layer deposition method.

Abstract: A method of operating a vehicle powertrain includes determining a selected powertrain operational mode. A demand fraction is determined. An internal combustion engine (ICE) is to output a maximum power when a gaseous fuel is conveyed to an injector of the ICE at a source pressure greater than a cutoff pressure. The source pressure in a container in fluid connection with the injector is determined. The gaseous fuel is received at the source pressure by the injector to inject the gaseous fuel into the ICE for combustion in response to the source pressure, demand fraction, or selected powertrain operation mode meeting a first set of criteria. The injector is prevented from injecting the gaseous fuel into the ICE and the powertrain is driven from an alternative power source in response to the source pressure, demand fraction, or selected powertrain operation mode meeting a second set of criteria.

Abstract: A battery pack with a drain plug and a circuit to detect when a liquid coolant has entered the battery pack. The drain plug includes a carrier defining a cavity internal to the carrier, an inlet disposed on a first surface of the carrier and an outlet disposed on a second surface of the carrier where the first surface and the second surface fluidly displaced from one another and coupled to the cavity. A soluble plug may be disposed within the cavity of the carrier; the soluble plug is configured to at least partially dissolve when fluidly coupled with a coolant allowing a portion of the coolant to flow between the inlet and the outlet and out of the battery pack. A strain gauge cooperative with the carrier such that a measured resistance change in the strain gauge corresponds to the soluble plug in contact with the liquid coolant. An associated circuit with the drain plug provides notification of the activation of the drain plug to the on-board computer systems.

Abstract: One variation may include a method which may include depositing a hydrophilic coating over at least a portion of a fuel cell bipolar plate. The bipolar plate may include a reactant gas header opening communication with the plurality of tunnels. Moreover, the tunnels may be communicating with a plurality of channels which may be defined by reactant gas flow field which may include a plurality of lands. At least a portion of the hydrophilic coating may be reacted with the material including a hydrophobic group which may provide a hydrophobic portion. Thereafter, at least a portion of the hydrophobic portion comprising oxidizing the hydrophobic group may be removed in order to regenerate the hydrophilic coating.

Abstract: Use of a flexible, nonconductive, porous, and thermally tolerant ceramic material as a separator in a lithium-ion battery or lithium-sulfur battery is described. The separator can be made of aluminum oxide and provides excellent mechanical and thermal properties that prevent wear and puncture of the separator caused by particles removed from the electrodes during the charging and discharging process. The separator is designed to mitigate effects of melt shrinkage and facilitate the lithium ion transport, in contrast to separators that include a polymeric material, thus preventing short-circuiting between the positive and the negative electrode. Improved wetting and filling of the separator with electrolyte solution are provided, for improved rate capability of the battery (fast charging and discharging). The separator further reduces the potential for thermal runaway in Li batteries.

Abstract: One embodiment of the invention includes an assembly of metal oxide comprising valve metal oxide nanotubes.

Abstract: One exemplary embodiment discloses a bipolar plate assembly including a cathode plate and an anode plate. Each of the cathode plate and the anode plate includes a core material, a first surface material coupled to a first side of the core material, and a second surface material coupled to a second side of the core material, wherein the first surface material and the second surface material have a different composition from the core material.

Abstract: A fluid storage tank includes a plurality of tank sub-units disposed in an array. Each tank sub-unit of the plurality of tank sub-units has an aperture defined in at least one wall overlapping with another aperture defined in at least one adjacent tank sub-unit of the plurality of tank sub-units. Each tank sub-unit of the plurality of tank sub-units is in fluid communication with a single outlet port for selectively extracting a stored fluid from the tank. Each of the plurality of tank sub-units is in fluid communication with a single fluid fill port. The array of tank sub-units is tessellated into a three-dimensional volume. A shell is disposed in contact with a plurality of the tank sub-units to envelop the array. The single outlet port and the single fluid fill port pass through the shell.

Abstract: A flow field plate for fuel cell applications includes a metal with a non-crystalline carbon layer disposed over at least a portion of the metal plate. The non-crystalline carbon layer includes an activated surface which is hydrophilic. Moreover, the flow field plate is included in a fuel cell with a minimal increase in contact resistance. Methods for forming the flow field plates are also provided.

Abstract: Resistance spot welding of a steel workpiece to an aluminum or an aluminum alloy workpiece can be facilitated by replacing the refractory aluminum oxide-based layer(s) on at least the faying surface of the aluminum or aluminum alloy workpiece with a protective coating that is more conducive to the spot welding process. The protective coating may be a metallic coating or a metal oxide conversion coating. In a preferred embodiment, the protective coating is a coating of zinc, tin, or an oxide of titanium, zirconium, chromium, or silicon.

Abstract: A bipolar plate to reduce electrical contact resistance between the plate and a diffusion layer used in a fuel cell. The opposing surfaces of the plate define flow channels with upstanding lands interspersed between them. The lands of the plate form an electrically-conductive contact with a diffusion layer in the fuel cell. At least a portion of the electrically-conductive contact is made up of a nickel-based alloy that reduces the contact resistance between the plate and the diffusion layer as a way to achieve improved electric current density. In one form, the alloy can be used as the primary material in the plate, while in another, it can be used as a coating deposited onto a conventional stainless steel plate.

Abstract: One embodiment of the invention includes a process including providing an electrically conductive fuel cell component having a first face, and depositing a graphitic/conductive carbon film on the first face of the electrically conductive fuel cell component comprising sputtering a graphite target using a closed field unbalanced magnetron field.

Abstract: One exemplary embodiment may include a method comprising: depositing a solution comprising an organometallic compound on a substrate, drying the solution to provide a film of the organometallic compound and at least partially oxidizing an organic component of the organometallic compound to provide nanoparticles including metal oxides on the substrate which would have multiuse industrial applications.

Abstract: System and methods for mitigating battery damage in a vehicle including a liquid-cooled battery system. In certain embodiments, a system for mitigating damage caused by leaks of liquid coolant in a battery system may include a one or more coolant leak sensors. A coolant leak detection system communicatively coupled to the coolant leak sensors may be configured to detect an occurrence of a liquid coolant leak in the battery system based on information provided by the coolant leak sensors. One or more valves communicatively coupled with the coolant leak detection system may actuate by the coolant leak detection system when a leak of liquid coolant is detected, thereby allowing leaked liquid coolant to drain from the battery system.

Abstract: A tank for storing compressed natural gas (CNG) for fueling an automotive vehicle engine. The tank includes a container body for containing the CNG at a service pressure rating from about 20 MPa (megapascals) to about 30 MPa, the container body being formed from a single piece. The container body includes a head end region, a terminal end region distal to the head end region, and an intermediate region extending therebetween. The terminal end region and the head end region define an axial length of the container body. The container body is formed from an aluminum alloy. A valve member is operatively connected to, and in fluid communication with the container body via an opening defined in a wall of the container body. The container body wall has a thickness ranging from about 3 mm to about 10 mm.

Abstract: A thermal management system for a natural gas tank includes a container, and a cooling mechanism operatively positioned to selectively cool the container. A method for minimizing a loss of natural gas storage during refueling is also disclosed herein. In an example of the method, a cooling mechanism, which is operatively positioned to selectively cool a container of a natural gas storage tank, is initiated prior to a refueling event. This cools the container to a predetermined temperature.

Abstract: A method of storing and using natural gas (NG) in a vehicle includes selecting a vehicle having an NG tank for fueling an engine of the vehicle. The tank service pressure rating is 3600 psi (pounds per square inch) and an NG adsorbent is in the tank. A first quantity of NG is transferred into the tank from a first source having a first source pressure less than 725 psi. The adsorbent adsorbs a portion of the NG. After transferring the first quantity of NG, the engine is operated until NG is desorbed and consumed by the engine. NG is transferred into the tank from a second source to fill the tank to a second tank pressure of about 3600 psi. The adsorbent adsorbs some of the NG. After transferring the second quantity of the NG, the engine is operated until NG is desorbed and consumed by the engine.

Abstract: A natural gas storage system includes a container, a natural gas adsorbent positioned in the container, and a heating mechanism operatively positioned to selectively thermally activate the adsorbent. A method for improving efficiency of the natural gas storage system is also disclosed. A predetermined percentage of a capacity of the container for natural gas remaining in the container is identified. In response, a heating mechanism operatively positioned to selectively thermally activate the adsorbent is initiated. The adsorbent is heated and buffer adsorbed gas is released from the adsorbent.

Abstract: A fluid storage tank includes a plurality of tank sub-units disposed in an array. Each tank sub-unit of the plurality of tank sub-units has an aperture defined in at least one wall overlapping with another aperture defined in at least one adjacent tank sub-unit of the plurality of tank sub-units. Each tank sub-unit of the plurality of tank sub-units is in fluid communication with a single outlet port for selectively extracting a stored fluid from the tank. Each of the plurality of tank sub-units is in fluid communication with a single fluid fill port.