Abstract: A support frame assembly for holding a plurality of battery cells includes a first end frame having a first plurality of protruding strips, a second end frame having a second plurality of protruding strips, and a structural frame having a plurality of grooves for receiving the first plurality of protruding strips and the second plurality of protruding strips. The first end frame and the second end frame attach to the structural frame to hold a first battery cell, a second battery cell and a foam pad positioned between the first battery cell and the second battery cell. The structural frame has curved features therein for receiving a cooling assembly and a chamfered slot for receiving a cooling fin from the cooling assembly. The support frame assembly also includes interlocking features that mate to another support frame with a gap defined between adjacent support frames.

Abstract: A power distribution unit for a vehicle includes a fuel cell stack, a bracket connected to the fuel cell stack and including at least one mount adapted to be connected directly to a vehicle to directly interconnect the fuel cell stack to the vehicle, a connection feature, and a traction system communicated with the fuel cell stack and carried by at least one of the fuel cell stack and the bracket with the connection feature disposed between the traction system and said at least one of the fuel cell stack and the bracket so that the traction system is indirectly connected to the vehicle. In one implementation, the connection feature includes an elastomeric pad disposed between a housing of the traction system and a mount or the vehicle frame. The pad provides a so-called “soft mount” of the traction system to the vehicle.

Abstract: A support frame assembly for holding a plurality of battery cells includes a first end frame having a first plurality of protruding strips, a second end frame having a second plurality of protruding strips, and a structural frame having a plurality of grooves for receiving the first plurality of protruding strips and the second plurality of protruding strips. The first end frame and the second end frame attach to the structural frame to hold a first battery cell, a second battery cell and a foam pad positioned between the first battery cell and the second battery cell. The structural frame has curved features therein for receiving a cooling assembly and a chamfered slot for receiving a cooling fin from the cooling assembly. The support frame assembly also includes interlocking features that mate to another support frame with a gap defined between adjacent support frames.

Abstract: A battery module is described. The battery module includes a plurality of battery cells; a plurality of cooling fin assemblies, each cooling fin assembly positioned between two battery cells, the cooling fin assemblies comprising at least one cooling fin and a foot on at least one side of the cooling fin assemblies, the foot having a bottom and interlocking profiles on each end, the interlocking profiles on adjacent feet of the cooling fin assemblies interlocking the feet and forming a surface; and a heat sink contacting the surface of the interlocked feet. A method of cooling a battery module is also described.

Abstract: A thermal management system for a battery pack includes a plurality of main bodies disposed in a stack, an inlet conduit and an outlet conduit in fluid communication with the plurality of main bodies, and a retention panel coupled to the plurality of main bodies. The main bodies include a thermal fin and conduit and are formed using an extrusion process, which minimizes a weight of the thermal fin and heat sink while minimizing a cost of the thermal management system.

Abstract: A cooling system for a battery pack module with a plurality of battery cells includes a cooling plate assembly having a first side wall and a second side wall spaced apart from one another. The first and second side walls are connected by a base wall. The first side wall, the second side wall and the base wall have at least one flow channel formed therein. The first side wall has an inlet in fluid communication with the flow channel. The second side wall has an outlet in fluid communication with the flow channel. The cooling plate assembly is configured to be placed in heat transfer communication with the battery cells disposed between the first and second side walls. The cooling plate assembly permits a coolant to flow into the inlet, through the at least one flow channel, and out of the outlet to regulate a temperature of the battery cells.

Abstract: A battery module is described. The battery module includes a plurality of battery cells; a plurality of cooling fin assemblies, each cooling fin assembly positioned between two battery cells, the cooling fin assemblies comprising at least one cooling fin and a foot on at least one side of the cooling fin assemblies, the foot having a bottom and interlocking profiles on each end, the interlocking profiles on adjacent feet of the cooling fin assemblies interlocking the feet and forming a surface; and a heat sink contacting the surface of the interlocked feet. A method of cooling a battery module is also described.

Abstract: A thermal management system for a battery pack includes a plurality of main bodies disposed in a stack, an inlet conduit and an outlet conduit in fluid communication with the plurality of main bodies, and a retention panel coupled to the plurality of main bodies. The main bodies include a thermal fin and conduit and are formed using an extrusion process, which minimizes a weight of the thermal fin and heat sink while minimizing a cost of the thermal management system.

Abstract: A cooling system for a battery pack module with a plurality of battery cells includes a cooling plate assembly having a first side wall and a second side wall spaced apart from one another. The first and second side walls are connected by a base wall. The first side wall, the second side wall and the base wall have at least one flow channel formed therein. The first side wall has an inlet in fluid communication with the flow channel. The second side wall has an outlet in fluid communication with the flow channel. The cooling plate assembly is configured to be placed in heat transfer communication with the battery cells disposed between the first and second side walls. The cooling plate assembly permits a coolant to flow into the inlet, through the at least one flow channel, and out of the outlet to regulate a temperature of the battery cells.

Abstract: A fuel tank assembly includes a fuel tank, a bracket carried by the fuel tank and having a portion accessible from the outside of the fuel tank to permit the assembly to be mounted to a vehicle, and an outer layer disposed around at least part of the fuel tank and a portion of the bracket to connect the bracket to the fuel tank. In one implementation, the fuel tank includes layers of composite material that have fibers embedded in resin or the like. The bracket is carried or trapped between adjacent layers of the composite material so that the bracket is fixed to the tank. The bracket preferably is connected to the tank at one end and is flexible in at least one direction to accommodate changes in the shape or dimensions of the fuel tank.

Abstract: An anode inlet unit for a split fuel cell stack or two fuel cell stacks having two anode inlets. The anode inlet unit has particular application for a small vehicle that requires less power. In one embodiment, the anode inlet unit only includes three injectors. Two of the injectors provide flow control for the hydrogen gas to the two anode inlets to provide the desired turn-down ratio. For a split stack design, the two injectors may provide flow-shifting where the injection of hydrogen gas into the sub-stacks is alternated. The other injector injects a small amount of hydrogen into the cathode side of the fuel cell stack at system start-up to quickly increase the operating temperature of the system. Additionally, two valves can be provided in the unit that receive a flow of air to purge the anode side of the stack for system shut-down.

Abstract: A fuel tank assembly includes a fuel tank, a bracket carried by the fuel tank and having a portion accessible from the outside of the fuel tank to permit the assembly to be mounted to a vehicle, and an outer layer disposed around at least part of the fuel tank and a portion of the bracket to connect the bracket to the fuel tank. In one implementation, the fuel tank includes layers of composite material that have fibers embedded in resin or the like. The bracket is carried or trapped between adjacent layers of the composite material so that the bracket is fixed to the tank. The bracket preferably is connected to the tank at one end and is flexible in at least one direction to accommodate changes in the shape or dimensions of the fuel tank.

Abstract: A power distribution unit for a vehicle includes a fuel cell stack, a bracket connected to the fuel cell stack and including at least one mount adapted to be connected directly to a vehicle to directly interconnect the fuel cell stack to the vehicle, a connection feature, and a traction system communicated with the fuel cell stack and carried by at least one of the fuel cell stack and the bracket with the connection feature disposed between the traction system and said at least one of the fuel cell stack and the bracket so that the traction system is indirectly connected to the vehicle. In one implementation, the connection feature includes an elastomeric pad disposed between a housing of the traction system and a mount or the vehicle frame. The pad provides a so-called “soft mount” of the traction system to the vehicle.

Abstract: A freeze capable compact fuel cell system to facilitate improved humidification in dry operating conditions and improved freeze capability as well as to facilitate improved removal of excess water and trapped nitrogen gas from the fuel cell system. The fuel cell system is particularly adapted for integration into a small vehicle body.

Abstract: An anode inlet unit for a split fuel cell stack or two fuel cell stacks having two anode inlets. The anode inlet unit has particular application for a small vehicle that requires less power. In one embodiment, the anode inlet unit only includes three injectors. Two of the injectors provide flow control for the hydrogen gas to the two anode inlets to provide the desired turn-down ratio. For a split stack design, the two injectors may provide flow-shifting where the injection of hydrogen gas into the sub-stacks is alternated. The other injector injects a small amount of hydrogen into the cathode side of the fuel cell stack at system start-up to quickly increase the operating temperature of the system. Additionally, two valves can be provided in the unit that receive a flow of air to purge the anode side of the stack for system shut-down.