Abstract: Methods for preparing a silicon-based electroactive material for use in an electrochemical cell are provided. The methods include heating a silicon oxide (SiOx, where 0.1?x?2) particle to a temperature between about 600° C. and about 1200° C. over a period between about 30 minutes and about 10 hours to form the silicon-based electroactive material, where the silicon-based electroactive material includes a silicon oxide matrix and a plurality of silicon crystallites embedded therein. In certain instances, the heating may occur in an inert atmosphere such that the silicon crystallites are distributed throughout the silicon oxide matrix. In other instances, the heating may occur in a reducing environment such that the silicon crystallites are condensed in one or more regions in the silicon oxide matrix. In each instance, the silicon-based electroactive material may be carbon coated by heating the silicon-based electroactive material in an environment including hydrocarbons.

Abstract: The present disclosure provides an electrolyte system for an electrochemical cell that cycles lithium ions. The electrolyte system may include an aliphatic fluorinated disulfonimide lithium salt in a mixture of organic solvents. The mixture of organic solvents may include a first solvent and a second solvent. The first solvent may include an ether solvent, a carbonate solvent, or a mixture of ether and carbonate solvents. The second solvent may include a fluorinated ether. A molar ratio of the aliphatic fluorinated disulfonimide lithium salt to the first solvent may be greater than or equal to about 1:1.2 to less than or equal to about 1:2. A molar ratio of the first solvent to the second solvent may be greater than or equal to about 1:1 to less than or equal to about 1:4.

Abstract: In some variations, an apparatus provides real-time monitoring of voltage and differential voltage of both anode and cathode in a battery configured with at least one reference electrode. Voltage monitors are connected to a computer programmed for receiving anode voltage signals; receiving cathode voltage signals; calculating the derivative of the anode voltage with respect to time or with respect to capacity; and calculating the derivative of the cathode voltage with respect to time or with respect to capacity. Other variations provide an apparatus for real-time assessment of capacities of both anode and cathode in a battery, comprising a computer programmed for receiving electrode voltage signals; estimating first and second electrode open-circuit voltages at two different times, and correlating the first and second electrode open-circuit voltages to first and second electrode states of charge, respectively, for each of anode and cathode. The anode and cathode capacities may then be estimated independently.

Abstract: A lithium-ion battery structure with a third electrode as reference electrode is disclosed. The reference electrode may be fabricated from lithium metal, lithiated carbon, or a variety of other lithium-containing electrode materials. A porous current collector allows permeation of reference lithium ions from the reference electrode to the cathode or anode, enabling voltage monitoring under actual operation of a lithium-ion battery. The reference electrode therefore does not need to be spatially between the battery anode and cathode, thus avoiding a shielding effect. The battery structure includes an external reference circuit to dynamically display the anode and cathode voltage. The battery structure can result in improved battery monitoring, enhanced battery safety, and extended battery life.

Abstract: In some variations, an apparatus provides real-time monitoring of voltage and differential voltage of both anode and cathode in a battery configured with at least one reference electrode. Voltage monitors are connected to a computer programmed for receiving anode voltage signals; receiving cathode voltage signals; calculating the derivative of the anode voltage with respect to time or with respect to capacity; and calculating the derivative of the cathode voltage with respect to time or with respect to capacity. Other variations provide an apparatus for real-time assessment of capacities of both anode and cathode in a battery, comprising a computer programmed for receiving electrode voltage signals; estimating first and second electrode open-circuit voltages at two different times, and correlating the first and second electrode open-circuit voltages to first and second electrode states of charge, respectively, for each of anode and cathode. The anode and cathode capacities may then be estimated independently.

Abstract: A lithium-ion battery structure with a third electrode as reference electrode is disclosed. The reference electrode may be fabricated from lithium metal, lithiated carbon, or a variety of other lithium-containing electrode materials. A porous current collector allows permeation of reference lithium ions from the reference electrode to the cathode or anode, enabling voltage monitoring under actual operation of a lithium-ion battery. The reference electrode therefore does not need to be spatially between the battery anode and cathode, thus avoiding a shielding effect. The battery structure includes an external reference circuit to dynamically display the anode and cathode voltage. The battery structure can result in improved battery monitoring, enhanced battery safety, and extended battery life.

Abstract: In an assembly of facing metal sheets separated by a polymer layer, welded metallurgical bonds are formed between the metal sheets by use of a friction stir weld tool. A rotating tool penetrates the first sheet, locally displaces the encountered portion of polymer film and penetrates into the second sheet. The affected metal of the two sheets is momentarily plasticized and stirred, and the plasticized metal of the two sheets combines to form a weld between the metal sheets. The interposed polymer film may be intended to serve as an adhesive or a vibration damping medium or the like. The facing metal sheets can be layers of facing laminated metal sheet structures that each comprise two metal sheets bonded by an adhesive interlayer.

Abstract: A method for determining a voltage based or current based state of charge (SOC) and state of health (SOH) of a battery system is provided. The method includes: providing a model of the battery system including an equivalent circuit having both low frequency and high frequency elements; establishing a plurality of functional relationships comprising relationship of the equivalent circuit with SOC; reducing at least part of the plurality of functional relationships into a set of time segmented recursive functional relationships, wherein a state at a first time t can be modeled by a functional presentation of a state at a second time t??t that occurred before the first time t; and computing a set of data points based upon the set of time segmented recursive functional relationships using a matrix for operation in matrix algebra.

Abstract: There is provided a method and article of manufacture for monitoring an electrical energy storage device for a system. The method comprises stabilizing the electrical energy storage device. Once the device is stabilized, a discrete electrical load is cyclically applied to the electrical energy storage device and state variables of the electrical energy storage device are monitored. A resistance of the electrical energy storage device is determined, and a remaining useful life parameter of the electrical energy storage device is determined based upon the determined resistance.

Abstract: The invention provides a method for manufacturing a powertrain component enclosure member, including the steps of: (A) positioning at least one insert into a mold, wherein the insert is provided with a coating to prevent bonding between the insert and the casting material; and (B) casting a wall of the powertrain component enclosure member in the mold around the insert such that a major portion of the insert is substantially non-bonded with the casting material to provide a proper interfacial boundary with the casting material for damping.

Abstract: One side of a metal sheet is joined to a polymer layer by applying heat to a joining area on the opposite side of the metal. The heat flows through the thin metal to activate a thermoplastic material or heat setting polymer into a bond with the metal. The method can be used to bond the metal sheet to a plastic body or another metal member. It is preferred to use a friction or friction stir tool to heat the metal surface.

Abstract: A recursive algorithm is provided for adaptive multi-parameter regression enhanced with forgetting factors unique to each regressed parameter. Applications of this algorithm can include lead acid batteries, nickel-metal hydride batteries, and lithium-ion batteries, among others. A control algorithm is presented, having an arbitrary number of model parameters, each having its own time-weighting factor. A method to determine optimal values for the time-weighting factors is included, to give greater effect to recently obtained data for the determination of a system's state. A methodology of weighted recursive least squares is employed, wherein the time weighting corresponds to the exponential-forgetting formalism. The derived mathematical result does not involve matrix inversion, and the method is iterative, i.e. each parameter is regressed individually at every time step.

Abstract: A fuel cell system that employs a matched battery that matches the battery voltage to a fuel cell power bus voltage so as to eliminate the need for a DC/DC converter. The internal characteristics and parameters of the matched battery allow it to operate over the large load dependent voltage swing of the fuel cell, and prevent the battery state of charge from going below a damaging value. The battery type, number of battery cells and the battery internal impedance are selected to provide the desired matching. In one embodiment, the battery is a lithium ion battery. The system also includes a diode electrically coupled to the power bus line and a by-pass switch electrically coupled to the power bus line in parallel with the diode. The by-pass switch is selectively opened or closed to allow the fuel cell stack to recharge the battery and prevent the battery from being overcharged.

Abstract: A vehicle having a chassis with a body and a drive train disposed on the chassis is disclosed. The drive train includes a metal housing having a void and a damping element disposed within the void. Also disclosed is a controller for damping vehicle noise that includes a processing circuit for executing instructions for: receiving a signal representative of a sensed vibration at a metal housing of the vehicle; in response to the sensed vibration, generating a control signal to activate a camping element disposed at a void within the metal housing; and causing the damping element to change in such a manner as to change the damping characteristics at the void of the metal housing.

Abstract: A powertrain includes an engine, a multi-speed transmission connected to a final drive, and a selectively engageable magnetorheological fluid clutch drivingly connected between the engine and multi-speed transmission. A motor/generator is operatively connected to the engine and the magnetorheological fluid clutch for selectively exchanging power with the engine and/or the magnetorheological fluid clutch such that the motor/generator may be used to start the engine, to drive the multi-speed transmission, and to receive energy from the magnetorheological fluid clutch for regenerative braking.

Abstract: A fixture device generally includes a base member, a reconfigurable pad comprising a shape memory material configured to selectively conform to a surface contour of a workpiece, and a thermoelectric unit in operative communication with the shape memory material of the reconfigurable pad. A process for operating a fixture device includes passing a current in a first direction through a thermoelectric unit in operative communication with a reconfigurable pad in an amount effective to heat a shape memory material therein to or above a shape setting temperature, contacting a surface of a workpiece with the reconfigurable pad, cooling the shape memory material below the shape setting temperature, and fixturing the workpiece with the fixture device.

Abstract: Pistons reciprocating in cylinders of a hydrocarbon-fueled internal combustion engine tend to trap air and unburned fuel between the top of the piston head and its enclosing cylinder wall. The circumferential side surface (or land) of the piston head above its upper piston ring groove is provided with a thin coating of porous aluminum oxide. Particles of an oxidation catalyst for the engine's fuel are electrolytically deposited in the pores of the oxide coating. During engine operation the oxide-supported catalyst particles promote combustion of the entrained fuel.

Abstract: Seal assemblies employing reversible thermally expandable and/or contractible material that can be controlled and remotely changed to alter the seal effectiveness, wherein the seal assemblies actively change dimensional and/or modulus properties such as stiffness, shape orientation, and the like. In this manner, in seal applications such as a vehicle door application, door opening and closing efforts can be minimized yet seal effectiveness can be maximized.

Abstract: A Coulomb friction damped disc brake rotor, wherein damping is provided Coulomb friction in generally coextensive relation with the braking surfaces of the one or more rotor cheeks. The Coulomb friction damped disc brake rotor has at least one interfacial boundary formed in at least one rotor cheek disposed in generally coextensive relation to the braking surface thereof. The interfacial boundary provides a mechanically distinguishable surface boundary between two surfaces which are in mutual contact such that a state of Coulomb friction exists therebetween.

Abstract: A method of generating electrical current in a system comprising a power-plant unit and/or hydrogen storage medium by transferring heat generated by the hydrogen storage medium and/or power-plant unit to a thermoelectric device, and converting the heat to generate electrical current using the thermoelectric device.