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: A reduced-corrosion assembly includes a first and a second component joined by a fastener having a head and a body. A coating covers a section of the body. The assembly also includes a washer, a compression limiter, and a nut arranged on the first component and adapted to engage the fastener body to thereby tighten the assembly. When the assembly is tightened, the compression limiter is arranged on the fastener body between the first and second components, while the second component is arranged on the fastener body between the compression limiter and the washer. Furthermore, the washer is arranged on the fastener body between the fastener head and the second component, while the coating covers the body substantially up to where the nut engages the body such that corrosion of the assembly is limited or reduced. A vehicle employing the reduced-corrosion fastening system is also provided.

Abstract: An apparatus for supporting a battery comprises a tray including a support surface, a recess having a elevation that is lower than an elevation of the support surface, ribs located in the recess and extending to the elevation of the support surface, thermal insulation supported on the ribs and the upper surface, and a battery contacting the insulation and supported on the ribs and the support surface.

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: 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: A drain plug assembly that has particular application for sealing a drain hole in a high voltage battery compartment on a vehicle. The plug assembly includes a plug that inserted into the drain hole. The plug assembly further includes a return spring coupled to the plug and causing the plug to be biased into the drain hole. The plug assembly also includes at least one shape memory alloy device coupled to the plug and a support structure. The SMA device receives an electrical current that causes the device to contract and move the plug out of the drain hole against the bias of the return spring.

Abstract: A battery module for an electric vehicle includes an auxiliary power module (APM) and at least one battery pack assembly. The battery pack assembly includes a plurality of battery frames, each with at least one battery cell disposed within it, and a plurality of cooling plates, each in thermal communication with at least one battery cell. The cooling plates have an inlet and an outlet connected by at least one coolant channel through which coolant is circulated to cool the battery cells. The APM may also require cooling, in which case the battery module may further include at least one additional cooling plate in thermal communication with the APM. The APM and the battery pack assembly are held together under compression such that they may share a common cooling system, and coolant may flow through the APM and/or the battery pack assembly to the cooling plates.

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 battery pack with a drain plug. 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 first lead and a second lead are configured to signally connect an impedance element that is cooperative with the carrier, to a circuit such that when the continuity of the circuit is interrupted, the circuit provides notification of the activation of the drain plug to the on-board computer systems.

Abstract: A battery module for an electric vehicle includes an auxiliary power module (APM) and at least one battery pack assembly. The battery pack assembly includes a plurality of battery frames, each with at least one battery cell disposed within it, and a plurality of cooling plates, each in thermal communication with at least one battery cell. The cooling plates have an inlet and an outlet connected by at least one coolant channel through which coolant is circulated to cool the battery cells. The APM may also require cooling, in which case the battery module may further include at least one additional cooling plate in thermal communication with the APM. The APM and the battery pack assembly are held together under compression such that they may share a common cooling system, and coolant may flow through the APM and/or the battery pack assembly to the cooling plates.

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 reduced-corrosion assembly includes a first and a second component joined by a fastener having a head and a body. A coating covers a section of the body. The assembly also includes a washer, a compression limiter, and a nut arranged on the first component and adapted to engage the fastener body to thereby tighten the assembly. When the assembly is tightened, the compression limiter is arranged on the fastener body between the first and second components, while the second component is arranged on the fastener body between the compression limiter and the washer. Furthermore, the washer is arranged on the fastener body between the fastener head and the second component, while the coating covers the body substantially up to where the nut engages the body such that corrosion of the assembly is limited or reduced. A vehicle employing the reduced-corrosion fastening system is also provided.

Abstract: A drain plug assembly that has particular application for sealing a drain hole in a high voltage battery compartment on a vehicle. The plug assembly includes a plug that inserted into the drain hole. The plug assembly further includes a return spring coupled to the plug and causing the plug to be biased into the drain hole. The plug assembly also includes at least one shape memory alloy device coupled to the plug and a support structure. The SMA device receives an electrical current that causes the device to contract and move the plug out of the drain hole against the bias of the return spring.

Abstract: An apparatus for supporting a battery comprises a tray including a support surface, a recess having a elevation that is lower than an elevation of the support surface, ribs located in the recess and extending to the elevation of the support surface, thermal insulation supported on the ribs and the upper surface, and a battery contacting the insulation and supported on the ribs and the support surface.