Abstract: A battery cell separator according to an exemplary aspect of the present disclosure includes, among other things, a top surface and a bottom surface. A body extends between the top surface and the bottom surface and includes a first contoured surface on a first side of the body and a second contoured surface on a second side. The first contoured surface and the second contoured surface converging between the top surface and a center of the body and diverging between the center and the bottom surface.

Abstract: A battery pack according to an exemplary aspect of the present disclosure includes, among other things, an enclosure that establishes a vent chamber and tubing in fluid communication with the vent chamber. A check valve is mounted outside of the enclosure and is connected to the tubing. The check valve permits flow of battery vent byproducts in a first direction but blocks the flow of atmospheric air in a second, opposite direction.

Abstract: A battery system according to an exemplary aspect of the present disclosure includes, among other things, a battery pack, a first sensor at an inlet of the battery pack and a second sensor at an outlet of the battery pack.

Abstract: A radiator according to an exemplary aspect of the present disclosure includes, among other things, a first zone that includes a first fan coverage area and a second zone that includes a second fan coverage area that is different from the first fan coverage area.

Abstract: A battery assembly may include an array of battery cells each having upper and lower ends, a face extending therebetween and partially defining an exterior of the array, and terminals extending from the upper end. The battery assembly may also include an exo-support structure including a plurality of retainer segments configured to support the upper and lower ends and a thermal plate defining one or more channels extending along the exterior of the array. The thermal plate may be arranged to thermally communicate with the battery cells via the faces. The exo-support structure may further include another thermal plate defining one or more channels extending along another exterior of the array which are arranged to thermally communicate with the cells. The battery assembly may include at least one cell separator made of a thermally conductive material which is located between two adjacent cells.

Abstract: A vehicle is provided including a battery module with front and rear battery cell arrays arranged generally parallel to and spaced apart from one another. The battery module includes a cover having an inlet port proximate to the front battery cell array and arranged obliquely thereto. A blower unit is configured to draw air through the inlet port such that a first portion of the air travels into the front battery cell array. A tray cooperates with the front battery cell array to define a passageway configured to direct a second portion of the air underneath the front battery cell array. The tray also defines a ramp underneath, and extending substantially a length of, the rear battery cell array and is configured to direct the second portion of air into the rear array.

Abstract: An illustrative embodiment of a cable joint integrity detection systems for an electric vehicle includes an electric vehicle power converter module; a fastener joint on the power converter module; vehicle wiring connections electrically interfacing with the power converter module at the fastener joint; a current sensor electrically interfacing with the fastener joint; and a controller interfacing with the current sensor, the current sensor transmits a sensor signal to the controller to ensure connectional integrity between the fastener joint and the vehicle wiring connections. Cable joint integrity detection methods are also disclosed.

Abstract: A vehicle is provided including a battery module, a DC/DC converter module portioned from the battery module, a duct, one blower, and a jumper duct. The battery module includes inlet and outlet ports. The DC/DC converter module includes inlet and outlet ports. A duct is arranged to direct cooling air into each of the inlet ports. The blower is arranged to draw cooling air from the duct, through the modules, and out the outlet ports. The jumper duct is arranged up stream of the blower with the converter outlet port, and configured to reduce an effective cross sectional area of the converter outlet port to define a flow rate of the cooling air into the battery inlet port.

Abstract: A vehicle is provided including a battery module, a DC/DC converter module portioned from the battery module, a duct, one blower, and a jumper duct. The battery module includes inlet and outlet ports. The DC/DC converter module includes inlet and outlet ports. A duct is arranged to direct cooling air into each of the inlet ports. The blower is arranged to draw cooling air from the duct, through the modules, and out the outlet ports. The jumper duct is arranged up stream of the blower with the converter outlet port, and configured to reduce an effective cross sectional area of the converter outlet port to define a flow rate of the cooling air into the battery inlet port.

Abstract: A vehicle is provided including a battery pack with an exhaust port, an air extractor spaced away from the exhaust port, and other vehicle components. A cargo tub and one or more trim panels are arranged to define a duct spanning from the exhaust port, across the vehicle and to an air extractor spaced away from the exhaust port. Air flows along the duct en route to outside the vehicle via the air extractor. The vehicle may also include a cabin and an inlet to the cabin spaced away from the exhaust port. The cargo tub and one or more trim panels may also be arranged to define a recirculation path from the duct to the inlet such that a portion of the air exiting the exhaust port flows along the recirculation path to the cabin via the inlet.

Abstract: A battery system includes a battery cover, a battery access panel removably connected to the battery cover, and a service disconnect switch. The service disconnect switch includes an electrical interlock switch. The service disconnect switch has a first position cooperating with the battery access panel to prevent removal of the access panel from the battery cover. In the first position, the service disconnect connects a traction battery to circuitry. The service disconnect also has a second position, the second position being displaced from the access panel and disconnecting the battery.

Abstract: A vehicle is provided including a battery module with front and rear battery cell arrays arranged generally parallel to and spaced apart from one another. The battery module includes a cover having an inlet port proximate to the front battery cell array and arranged obliquely thereto. A blower unit is configured to draw air through the inlet port such that a first portion of the air travels into the front battery cell array. A tray cooperates with the front battery cell array to define a passageway configured to direct a second portion of the air underneath the front battery cell array. The tray also defines a ramp underneath, and extending substantially a length of, the rear battery cell array and is configured to direct the second portion of air into the rear array.

Abstract: In at least one embodiment, a purge system for a fuel cell stack is provided. The system comprises a blower, a differential pressure sensor and a purge valve. The blower delivers a recirculated gas back to the stack at varying electrical power levels and blower speeds. The differential pressure sensor senses pressure of the recirculated gas across the blower. The purge valve purges the recirculated gas based on at least one of a blower power level, a blower speed, and the pressure of the recirculated gas.

Abstract: A system for delivering an input fuel stream to a fuel cell stack to generate electrical current and to discharge an unused fuel stream is provided. A supply produces a supply fuel stream. An ejector combines a purged fuel stream and the supply fuel stream and controls the flow of the input fuel stream to the fuel cell stack. A purging arrangement receives the unused fuel stream which includes impurities and purges the impurities from the unused fuel stream to generate the purged fuel stream. A bypass valve is capable of delivering the purged fuel stream to the ejector. A blower is capable of delivering the purged fuel stream to the ejector. A controller controls one of the bypass valve and the blower for delivering the purged fuel stream to the ejector based on the amount of electrical current generated by the fuel cell stack.

Abstract: A fuel cell system may include a fuel cell stack, a manifold in fluid communication with the stack, and a pressure sensor. The pressure sensor may include a housing defining a chamber in fluid communication with the manifold, a pressure sensing element disposed within the chamber, and a heating element disposed within the chamber.

Abstract: In at least one embodiment, a purge system for a fuel cell stack is provided. The system comprises a blower, a differential pressure sensor and a purge valve. The blower delivers a recirculated gas back to the stack at varying electrical power levels and blower speeds. The differential pressure sensor senses pressure of the recirculated gas across the blower. The purge valve purges the recirculated gas based on at least one of a blower power level, a blower speed, and the pressure of the recirculated gas.

Abstract: A fuel cell system includes a primary hydrogen source capable of communicating with a fuel cell anode. The system also includes a secondary hydrogen source communicating with the primary hydrogen source. A first valve is positioned downstream of the secondary hydrogen source. The valve allows hydrogen from the secondary source to communicate with hydrogen from the primary source downstream of the valve and upstream of the fuel cell anode.

Abstract: In at least one embodiment, a fuel cell anode exhaust system includes a fuel cell anode having an input and an output. The system also includes a first conduit loop communicating with the anode input and output. The system also includes a second conduit loop having an input and an output. The input and output communicate with the first conduit loop. A gas separator is disposed on the second conduit loop for purifying an exhaust stream fed into the gas separator.

Abstract: A system and method is provided for preventing disengagement between an electrical plug and a charge port on an electric vehicle. One or more projections are disposed on the electric vehicle. The projection has an extended locked position and a retracted unlocked position. An actuator selectively extends and retracts the projection between the locked and unlocked positions. When the projection is in the locked position, the projection engages the plug and prevents disengagement of the plug and the port.

Abstract: A system and method is provided for preventing disengagement between an electrical plug and a charge port on an electric vehicle. One or more projections are disposed on the electric vehicle. The projection has an extended locked position and a retracted unlocked position. An actuator selectively extends and retracts the projection between the locked and unlocked positions. When the projection is in the locked position, the projection engages the plug and prevents disengagement of the plug and the port.