Abstract: A multi-module battery pack includes a battery tray defining multiple battery tray compartments, battery modules each disposed within a corresponding one of the compartments, and a thermal barrier arranged in a predefined heat transfer path through the tray between an adjacent pair of the battery modules. The thermal barrier has a thickness of at least about 1 mm and a thermal conductivity of less than about 4 W/m-K, such that the thermal barrier blocks the heat transfer path to mitigate a thermal runaway event of one of the adjacent pair of battery modules. An electric powertrain system includes a rotary electric machine having phase leads and an output member, a driven load coupled to the output member, and the multi-module battery pack. A method includes providing the tray, identifying the heat transfer path, and arranging the thermal barrier in the heat transfer path.

Abstract: A multi-module battery pack includes a battery tray defining multiple battery tray compartments, battery modules each disposed within a corresponding one of the compartments, and a thermal barrier arranged in a predefined heat transfer path through the tray between an adjacent pair of the battery modules. The thermal barrier has a thickness of at least about 1 mm and a thermal conductivity of less than about 4 W/m-K, such that the thermal barrier blocks the heat transfer path to mitigate a thermal runaway event of one of the adjacent pair of battery modules. An electric powertrain system includes a rotary electric machine having phase leads and an output member, a driven load coupled to the output member, and the multi-module battery pack. A method includes providing the tray, identifying the heat transfer path, and arranging the thermal barrier in the heat transfer path.

Abstract: A thermal management system for an on-vehicle battery includes a battery, a first thermal element, a second thermal element, a battery mounting bracket, and a vehicle body structural element. The battery mounting bracket includes a first portion attached to the vehicle body structural element, and a second portion attached to the first thermal element. The first thermal element is attached to the first end portion of the battery, and the second thermal element is attached to at least one of the second end portion, the first and second side portions, the top portion or the bottom portion of the battery. The first thermal element is composed from a first phase-change material having a first phase-change temperature and the second thermal element is composed from a second phase-change material having a second phase-change temperature, wherein the first phase-change temperature is greater than the second phase-change temperature.

Abstract: A thermal management system for an on-vehicle battery includes a battery, a first thermal element, a second thermal element, a battery mounting bracket, and a vehicle body structural element. The battery mounting bracket includes a first portion attached to the vehicle body structural element, and a second portion attached to the first thermal element. The first thermal element is attached to the first end portion of the battery, and the second thermal element is attached to at least one of the second end portion, the first and second side portions, the top portion or the bottom portion of the battery. The first thermal element is composed from a first phase-change material having a first phase-change temperature and the second thermal element is composed from a second phase-change material having a second phase-change temperature, wherein the first phase-change temperature is greater than the second phase-change temperature.

Abstract: An electric vehicle includes a chassis frame and a battery pack disposed below and engaged to the chassis frame. The chassis frame includes a first cross member, and the battery pack includes a support structure having a first cross component. The first cross component co-extends with, and is engaged to, the first cross member.

Abstract: An electric vehicle includes a chassis frame and a battery pack disposed below and engaged to the chassis frame. The chassis frame includes a first cross member, and the battery pack includes a support structure having a first cross component. The first cross component co-extends with, and is engaged to, the first cross member.

Abstract: An electric vehicle includes a chassis frame, a battery pack, and a multi-shear fastener. The battery pack includes a support structure vertically spaced, at least in-part, from the chassis frame. The multi-shear fastener is constructed and arranged to attach the chassis frame to the support structure.

Abstract: An analytical methodology for the specification of progressive optimal compression damping of a suspension system to negotiate severe events, yet provides very acceptable ride quality and handling during routine events. In a broad aspect, the method provides a progressive optimal unconstrained damping response of the wheel assembly with respect to the body. In a preferred aspect, the method provides a progressive optimal constrained damping response of the wheel assembly with respect to the body, wherein below a predetermined velocity a conventional damper force is retained.

Abstract: A vehicle having an energy-absorbing device mountable to a bumper of the vehicle is provided. The energy-absorbing device is attached to a vehicle rail having an inner rail surface and an edge surface. The energy-absorbing device defines a first crush surface interfacing with the inner rail surface. In a first embodiment, the energy-absorbing device defines a second crush surface positioned to directly interface with the edge surface of the vehicle rail in the event of an impact. The energy-absorbing device is configured to transmit load received from the impact directly to the edge surface of the vehicle rail through the second crush surface. This results in an efficient joint for the energy-absorbing device.

Abstract: A vehicle having an energy-absorbing device mountable to a bumper of the vehicle is provided. The energy-absorbing device is attached to a vehicle rail having an inner rail surface and an edge surface. The energy-absorbing device defines a first crush surface interfacing with the inner rail surface. In a first embodiment, the energy-absorbing device defines a second crush surface positioned to directly interface with the edge surface of the vehicle rail in the event of an impact. The energy-absorbing device is configured to transmit load received from the impact directly to the edge surface of the vehicle rail through the second crush surface. This results in an efficient joint for the energy-absorbing device.

Abstract: An analytical methodology for the specification of progressive optimal compression damping of a suspension system to negotiate severe events, yet provides very acceptable ride quality and handling during routine events. In a broad aspect, the method provides a progressive optimal unconstrained damping response of the wheel assembly with respect to the body. In a preferred aspect, the method provides a progressive optimal constrained damping response of the wheel assembly with respect to the body, wherein below a predetermined velocity a conventional damper force is retained.