Abstract: Thermal barrier systems are provided for use within traction battery packs. An exemplary thermal barrier system may include one or more expandable gap fillers configured to transition from a compressed state to an uncompressed state when a temperature near the expandable gap filler exceeds a predefined temperature threshold. In the uncompressed state, the expandable gap filler reduces a free air volume of a void space of the traction battery pack, thereby managing or even preventing the transfer of thermal energy to nearby structures.

Abstract: A topping cycle fuel cell unit includes a support plate having internal flow passages that extend to combustion outlets, a first electrode layer, an electrolyte layer, and a second electrode layer. The second electrode layer is configured to be coupled to another support plate of another fuel cell unit. The internal flow passages are configured to receive and direct air across the first electrolyte layer or the second electrolyte layer and to receive and direct fuel across another of the first electrolyte layer or the second electrolyte layer such that the first electrode layer, the electrolyte layer, and the second electrode layer create electric current. The internal flow passages are configured to direct at least some of the air and at least some of the fuel to the combustion outlets where the at least some air and the at least some fuel is combusted.

Abstract: A battery pack assembly method includes compressing at least one cell stack, inserting the at least one cell stack into a cell-receiving opening of an enclosure structure, and pushing at least one cell of the at least one cell stack out of the enclosure structure using a pusher. Another traction battery pack assembly method includes moving a cell stack into an enclosure structure from a compression fixture that compresses the cell stack. The cell stack includes a plurality of battery cells. After the moving, the method compresses the cell stack using the enclosure structure. The method then includes establishing electrical connections between the battery cells of the cell stack, and testing the electrical connections prior to securing a busbar to the cell stack.

Abstract: An assay provides comprehensive genomic profiling for plasma-derived circulating tumor DNA from solid tumors. The assay covers genes for mutations including single nucleotide variants (SNVs), insertions and deletions (indels), copy number variants (CNVs), and fusions, as well as microsatellite instability (MSI) status. The assay may use a custom hybrid capture process with optimized chemistry and panel design, as well as novel algorithms for SNV, indel, and CNV data filtering to optimize performance.

Abstract: Thermal barrier assemblies are provided for inhibiting the transfer of thermal energy inside a traction battery pack while simultaneously accommodating battery cell swelling forces and providing sufficient structural stiffness. An exemplary thermal barrier assembly may include a structural barrier, a thermal insulation medium, and one or more flexible structures that are arranged to contain the thermal insulation medium within an outer perimeter provided by the structural barrier. The flexible structures may be configured as flexible links or film layers that are capable of mechanically isolating a first portion of the structural barrier that contacts a battery cell undergoing swelling from a second portion of the structural barrier that is not in contact with the battery cell, thereby providing uniform resistance to the battery cell swelling forces while also providing structural stiffness.

Abstract: Techniques are provided for electrically connecting groups of battery cells within a traction battery pack. The battery cells within each groping may include cell tab terminals of a common length for direct welding relative to a cross-member assembly. Groups of cell tab terminals may be received through cell tab openings of the cross-member assembly and then bent into place relative to a backing tab for welding. The cross-member assembly may include various lead-in and bending features that facilitate cell tab terminal bending and welding.

Abstract: A method of assembling a battery pack includes inserting a guide within a slot of a slotted assembly; guiding one or more terminals into the slot using the guide; and withdrawing the guide from the slot while the one or more terminals remain in the slot. A traction battery pack assembly includes a terminal guide; and an actuator assembly that rotates the terminal guide back and forth between a guiding position and a withdrawn position. The terminal guide is at least partially disposed within a slot of a slotted assembly when in the guiding position such that the terminal guide can guide insertion of one or more terminals into the slot. The terminal guide is withdrawn from the slot when in the withdrawn position.

Abstract: Embodiments described herein relate to a tool comprising a cylindrical member having a cylindrical tube portion with a circular opening at a first end of the cylindrical member, and a protrusion disposed on an inner surface of the cylindrical tube portion. In various embodiments, the tool includes a plurality of protrusions that are disposed equal-distant from one another along a circumference on the inner surface of the cylindrical tube portion. In various embodiments, the cylindrical member comprises a second cylindrical tube portion with a second circular opening on a second end of the cylindrical member. In various embodiments, the protrusion has a varying height that gradually increases from a first end of the protrusion to a second end. In various embodiments, the protrusion is disposed at a slanted angle with respect to the circular opening where the first end is closer to the circular opening than the second end.

Abstract: A battery assembly includes at least one enclosure structure that is thermoformed about a battery assembly of a battery pack. A method of enclosing a battery assembly can include placing a sheet of material adjacent a battery assembly of a battery pack; and thermoforming the sheet of material about the battery assembly to provide an enclosure structure for the battery assembly.

Abstract: A structural assembly for an electric vehicle that includes a vehicle frame and a battery structure. The vehicle frame is distinct from a vehicle body. The vehicle frame includes a first section and a second section. The first section includes opposed longitudinal rails. The battery structure is configured to house power storage units and is disposed between the opposed longitudinal rails. The battery structure includes a battery housing that is secured to the opposed longitudinal rails of the first section. The first section and the battery housing are combined into a unitized structure that is removably secured to the second section of the vehicle frame.

Abstract: Traction battery packs are disclosed that include cell-to-pack battery systems. A cell stack/cell matrix of the cell-to-pack battery system may be positioned within an irregularly shaped enclosure tray of the traction battery pack. A block insert may be positioned at an interface between the cell stack/cell matrix and an irregularly shaped interior surface of the enclosure tray. The block insert may be configured to facilitate insertion of the cell stack/cell matrix into the enclosure tray, transfer compression loads from the enclosure tray walls to the cell stack/cell matrix, resist battery cell compression loads, etc.

Abstract: A motorized system includes a motor that drives rotation of an input shaft, a first gear system coupled with the input shaft, a spindle drive, and a measuring arrangement. The spindle drive has a driving element that is coupled with the first gear system, such that rotation of the input shaft prompts rotation of the driving element via the first gear system, and a driven element that is engaged with the driving element, such that rotation of the driving element drives axial movement of the driven element. The measuring arrangement includes a second gear system coupled with the input shaft, an indicator coupled with the second gear system, such that rotation of the input shaft prompts rotation of the indicator via the second gear system, and at least one limit switch with which the indicator interacts to control operation of the motor.

Abstract: A universal joint (U-joint) assembly transmits torque from a drive component to a driven component across an articulating joint. The U-joint assembly includes male and female U-joint members, a central ball joint, and a retaining device configured to secure the assembly in an assembled configuration. The female U-joint member includes a cavity extending into a receptacle end thereof. The cavity terminates in a circular receptacle and includes a plurality of rectangular channels extending radially outward from the cavity at equal intervals, each channel defined by three planar drive surfaces. The male U-joint member has a drive end with a plurality of corresponding rectangular extensions protruding from an outer periphery of the drive end, each extension including a plurality of axial angular surfaces. When assembled, each of the angular surfaces of the drive end opposes a corresponding one of the drive surfaces of the cavity. Other embodiments are also disclosed.

Abstract: A structural assembly for an electric vehicle includes a vehicle frame and a battery structure. The vehicle frame is distinct from a vehicle body and includes a front section, a rear section and a mid-section disposed between the front and rear sections. The mid-section includes opposed longitudinal rails. The battery structure is configured to house power storage units and is disposed between the opposed longitudinal rails. The battery structure includes a battery housing secured to the opposed longitudinal rails of the mid-section. The mid-section and the battery housing are combined into a unitized structure that is removably secured to the front and rear sections of the vehicle frame.

Abstract: Manufacturing processes are disclosed for assembling traction battery packs that include battery systems, such as cell-to-pack battery systems. An exemplary assembly method includes inserting one or more cell stacks of the cell-to-pack battery system into a cell-compressing opening of an enclosure tray. The method may involve the use of slider plates that provide sliding surfaces that facilitate the insertion of the cell stacks into the cell compressing opening.

Abstract: Described herein are preserved formulations of insulin-Fc fusions. The formulations include insulin-Fc fusions having prolonged pharmacokinetic and pharmacodynamic profiles sufficient for once weekly administration in the treatment of diabetes and are sufficiently stable to allow for storage and use without unacceptable loss of chemical or physical stability.

Abstract: A frame lit mirror component includes an extruded frame member. The extruded frame member further includes a mirror mounting edge. The mirror mounting edge extends along a longitudinal direction of the extruded frame member. The mirror mounting edge is sized to receive an edge of a mirror. A light source volume extends along the longitudinal direction of the extruded frame member. An angle exists between the mirror mounting edge and the light source volume. The light source volume is sized to receive a light source, such that when the light source is in an on-state light radiates from the light source volume.