Abstract: This disclosure is generally directed to systems and methods for optimizing a travel route of a hybrid-electric vehicle inside an emissions-free zone. In one exemplary embodiment, a travel route optimization system can be used to determine a charge level of a battery in the hybrid-electric vehicle and to locate charging stations inside and/or outside the emissions-free zone. The charge level provides an indication of a distance that the hybrid-electric vehicle can travel before a gasoline engine is started. The system can use factors such as the location of the charging stations and the charge level of the battery to generate an optimized travel route for the hybrid-electric vehicle that eliminates starting of the gasoline engine inside the emissions-free zone. The optimized travel route may be updated in real-time so as to allow recharging of the battery on an as-needed basis at a charging station inside or outside the emissions-free zone.

Abstract: An exemplary battery assembly includes an endwall, an endplate, and a flange secured within a recess to secure the endwall relative to the endplate. One of the endwall or the endplate provides the flange, and the other of the endwall or the endplate provides the recess.

Abstract: This disclosure is generally directed to systems and methods for optimizing a travel route of a hybrid-electric vehicle inside an emissions-free zone. In one exemplary embodiment, a travel route optimization system can be used to determine a charge level of a battery in the hybrid-electric vehicle and to locate charging stations inside and/or outside the emissions-free zone. The charge level provides an indication of a distance that the hybrid-electric vehicle can travel before a gasoline engine is started. The system can use factors such as the location of the charging stations and the charge level of the battery to generate an optimized travel route for the hybrid-electric vehicle that eliminates starting of the gasoline engine inside the emissions-free zone. The optimized travel route may be updated in real-time so as to allow recharging of the battery on an as-needed basis at a charging station inside or outside the emissions-free zone.

Abstract: A charge plate receiver assembly for an electric vehicle includes an inductive charge plate receiver and a swing arm pivotally secured to a mounting surface. The charge plate receiver is pivotally secured to the swing arm such that the charge plate receiver travels along an arc defined by a length of the swing arm when the assembly moves between a retracted position and a deployed position. When retracted, the charge plate receiver may retract into a cavity, defined by under-body components. The charge plate receiver has a planar surface and the planar surface is generally perpendicular to a horizontal plane of the vehicle in the retracted position and parallel with the horizontal plane of the vehicle in the deployed position.

Abstract: An exemplary battery assembly includes an endplate of a battery array, and an enclosure wall secured directly to the endplate from outside an open area of a battery pack enclosure. An exemplary method of securing a battery array includes positioning a battery array within an open area of an enclosure and, from a position outside the open area, securing an endplate of a battery array directly to a wall of a battery pack enclosure.

Abstract: A combination exhaust gas heat exchanger and noise reduction unit is disclosed, whereby a heat exchanger and a noise reduction member are arranged side-by-side and integrated as a unit. A heat exchanger outlet opens directly into a chamber of the noise reduction member. In one arrangement, a bypass valve serves to selectively direct exhaust gas into either the heat exchanger or the noise reduction member, depending on an operating condition of an associated engine.

Abstract: An exemplary method includes circulating a fluid along a fluid circuit that extends through a heat exchanger and a battery pack, and, during the circulating, heating the fluid with a flow of exhaust gas and using the fluid to heat the battery pack. An exemplary vehicle system includes a battery pack, a heat exchanger, a fluid circuit configured to circulate a fluid between the battery pack and the heat exchanger, and a valve moveable back and forth between a heating position and a cooling position. The valve in the heating position permits more flow along an exhaust circuit to heat the fluid in the fluid circuit than the valve in the cooling position.

Abstract: A battery system of a vehicle includes a battery, a battery tray configured to support the battery, and a battery pouch. The pouch has a plurality of side walls and a bottom defining a space sized to accommodate the battery. The side walls each include an absorbent layer containing a base, such as sodium bicarbonate, and an outer layer impervious to the electrolyte and the base. One of the side walls is a front side wall that includes a wedge that is configured to mate with a front of the battery and the tray. The wedge cooperates with a bottom lip of the battery to secure the battery to the tray.

Abstract: An exemplary method includes circulating a fluid along a fluid circuit that extends through a heat exchanger and a battery pack, and, during the circulating, heating the fluid with a flow of exhaust gas and using the fluid to heat the battery pack. An exemplary vehicle system includes a battery pack, a heat exchanger, a fluid circuit configured to circulate a fluid between the battery pack and the heat exchanger, and a valve moveable back and forth between a heating position and a cooling position. The valve in the heating position permits more flow along an exhaust circuit to heat the fluid in the fluid circuit than the valve in the cooling position.

Abstract: An exemplary battery assembly includes an endwall, an endplate, and a flange secured within a recess to secure the endwall relative to the endplate. One of the endwall or the endplate provides the flange, and the other of the endwall or the endplate provides the recess.

Abstract: An exemplary battery assembly includes an endplate of a battery array, and an enclosure wall secured directly to the endplate from outside an open area of a battery pack enclosure. An exemplary method of securing a battery array includes positioning a battery array within an open area of an enclosure and, from a position outside the open area, securing an endplate of a battery array directly to a wall of a battery pack enclosure.

Abstract: A battery assembly includes a thermal plate having a pair of opposing thermal surfaces and a coolant flow field defined therebetween. Each of the thermal surfaces defines at least one threaded hole that extends into the flow field. The battery assembly further includes first and second cell arrays each disposed against a different one of the thermal surfaces and attached to the thermal plate via a fastener received in one of the threaded holes.

Abstract: A battery system of a vehicle includes a battery, a battery tray configured to support the battery, and a battery pouch. The pouch has a plurality of side walls and a bottom defining a space sized to accommodate the battery. The side walls each include an absorbent layer containing a base, such as sodium bicarbonate, and an outer layer impervious to the electrolyte and the base. One of the side walls is a front side wall that includes a wedge that is configured to mate with a front of the battery and the tray. The wedge cooperates with a bottom lip of the battery to secure the battery to the tray.

Abstract: A charge plate receiver assembly for an electric vehicle includes an inductive charge plate receiver and a swing arm pivotally secured to a mounting surface. The charge plate receiver is pivotally secured to the swing arm such that the charge plate receiver travels along an arc defined by a length of the swing arm when the assembly moves between a retracted position and a deployed position. When retracted, the charge plate receiver may retract into a cavity, defined by under-body components. The charge plate receiver has a planar surface and the planar surface is generally perpendicular to a horizontal plane of the vehicle in the retracted position and parallel with the horizontal plane of the vehicle in the deployed position.

Abstract: A combination exhaust gas heat exchanger and noise reduction unit is disclosed, whereby a heat exchanger and a noise reduction member are arranged side-by-side and integrated as a unit. A heat exchanger outlet opens directly into a chamber of the noise reduction member. In one arrangement, a bypass valve serves to selectively direct exhaust gas into either the heat exchanger or the noise reduction member, depending on an operating condition of an associated engine.