Abstract: Electric vehicles and, more particularly, a control system for an all-wheel drive electric vehicle.

Abstract: A system and method for identifying and responding to exceptional charge events of series-connected energy storage elements.

Abstract: In a vehicle door assembly, controllers processes signals from an extension force sensor and a retraction force sensor to control a door handle. As a motor retracts the handle, a swing arm in the vehicle door presses against the retraction force sensor causing the handle controller to stop the motor. Pushing on the retracted handle presses the swing arm against the retraction force sensor a second time causing the controllers to operate the motor and extend the handle. As the handle extends, the swing arm presses against the extension force sensor and the handle controller stops the motor as the handle is fully extended. Subsequently, a hand pulling on the door handle presses the swing arm against the extension force sensor a second time causing the controllers to unlatch a latch holding the vehicle door shut, and thereby allow the vehicle door to open.

Abstract: An energy storage system includes: multiple cells, each cell having a first end with anode and cathode terminals, and a second end opposite the first end, the cells arranged so that the second ends are aligned; for each of the cells, electrical connections coupled to the anode and cathode terminals at the first end; and a heat pipe having a flat evaporation surface facing the second ends.

Abstract: A door handle assembly extends a door handle in parallel from an outer surface of a vehicle door and retracts the door handle until it is flush with the outer surface. The door handle assembly includes a door handle formed from a planar handle member and a handle base member. The planar handle member is coupled to the handle base member and a swing arm coupled to the backside of the handle base member extends and retracts the door handle. A first upper fork is rotably coupled to a backside of the handle base member near the distal portion of a first post portion and a second upper fork is rotably coupled to the backside of the handle base member near the distal portion of a second post portion. The lower dual fork portion of the swing arm pivots about a shaft mounted to an inner door surface.

Abstract: A liquid cooling system for an electric motor includes: a pump for liquid to cool the electric motor; a heat exchanger that removes heat from the liquid; a manifold extending above a stator of the electric motor, the manifold receiving the liquid under pressure and having a first opening that directs a first liquid jet onto the stator; and a first tray above first end turns of the stator, the manifold having a second opening that directs a second liquid jet onto the first tray, the first tray having a third opening that performs gravity-fed liquid distribution onto the first end turns.

Abstract: A charging system for an electric vehicle includes: a power supply; a cable having first and second ends, the first end attached to the power supply, the cable comprising a charging conductor and a cooling conduit, each of which extends from the first end to the second end; and a connector attached to the second end of the cable, the connector having a form factor corresponding to a charge port of the electric vehicle; wherein the cooling conduit is adapted to convey a fluid that cools the charging conductor.

Abstract: An active thermal runaway mitigation system is provided that mitigates the effects of a single cell undergoing thermal runaway, thereby preventing the propagation of the thermal runaway event to neighboring cells within the battery pack. The provided system includes at least one, fluid-containing conduit in proximity to the cells within the battery pack. The conduit includes a plurality of breach points in proximity to the subset of cells, where each breach point is configured to form a breach at a preset temperature that is lower than the melting temperature of the conduit. Once a breach is formed, the fluid contained within the conduit is discharged through the breach.

Abstract: A system for detecting thermal events, e.g., thermal runaway, within a sealed battery pack based on a characterization of monitored pressure variations within the pack is provided. The system includes at least one pressure sensor coupled to the battery pack and to a pressure monitoring system that outputs pressure data representative of the battery pack pressure over time; a system controller that analyzes the pressure data and outputs a control signal when the pressure data fits a specific curve shape; and a thermal event response subsystem that performs a preset response upon receipt of the control signal from the system controller. The system may include a secondary effect monitoring system, wherein the thermal event response subsystem performs the preset response when the pressure data fits a specific curve shape and the secondary effect is detected by the secondary effect monitoring system.

Abstract: A door handle assembly for a vehicle door includes a door handle operated using a controller and sensors. In the door interior, an upper portion of a swing arm connects to a first post and a second post portion of the door handle. The lower portion of the swing arm, rotably attached to a shaft on the inner door, pivots between an extended and retracted position. When an extension force sensor contacts the upper portion of the arm, the extension force sensor on the inner door surface generates an extension force response signal. A retraction force sensor on the lower portion of the arm generates a retraction force response signal when the retraction force sensor on the lower portion of the arm contacts a flush adjuster rod. Both extension and retraction force response signals are used by the controller to operate the door handle.

Abstract: A method for operating a vehicle user interface is provided, the user interface utilizing a touch-screen display mounted within the vehicle. In one aspect, the visual or visual/interactive properties of the interface change after the user initiates interface interaction. In another aspect, the interface allows a user to utilize any of a variety of different control interaction techniques, all to achieve the same function.

Abstract: A battery system is provided in which the batteries are mounted between a pair of substrates, the system further including at least one cooling tube mounted next to the batteries, the cooling tube used to withdraw heat from the batteries via a circulating liquid coolant.

Abstract: An electromagnetic switch includes: a stationary electrical contact; a moveable electrical contact; an actuated member to which the moveable electrical contact is attached for driving the moveable electrical contact into and out of contact with the stationary electrical contact; and a damping interface between the moveable electrical contact and the actuated member.

Abstract: A system for detecting cell failure within a battery pack based on variations in the measured electrical isolation resistance of the battery pack is provided. The system includes an electrical isolation resistance monitoring subsystem for monitoring the electrical isolation resistance of the battery pack; a system controller coupled to the isolation resistance monitoring subsystem that detects when the electrical isolation resistance falls below a preset value; and a cell failure response subsystem that performs a preset response upon receipt of a control signal from the system controller, where the control signal is transmitted when the electrical isolation resistance falls below the preset value. The system may include a secondary effect monitoring system, wherein the cell failure response subsystem performs the preset response when the electrical isolation resistance falls below the preset value and the secondary effect is detected by the secondary effect monitoring system.

Abstract: An energy absorbing and distributing side impact system for use with a vehicle is provided, the system utilizing a battery pack enclosure that includes a plurality of cross-members that transverse the battery pack enclosure and absorb and distribute at least a portion of the load received when either the first or second side of the vehicle receives a side impact. The battery pack enclosure is positioned between the front and rear vehicle suspension assemblies and mounted between, and mechanically coupled to, vehicle structural members (e.g., rocker panels) located on either side of the vehicle. In addition to providing rigidity, strength and impact resistance, the battery pack cross-members segregate the batteries contained within the battery pack enclosure into battery groups.

Abstract: A system and method for low-cost, fault tolerant, EMI robust data communications, particularly for an EV environment. A data communications method, including a) enabling a transmission of a wake signal from a host to a remote client through an isolator disposed at the remote client when the wake signal is asserted from the host at a host-portion of the isolator concurrent with a periodic enablement of a client-portion of the isolator by the remote client; and thereafter b) transmitting the wake signal from the host to the remote client through the isolator; c) controlling enablement of the client-portion responsive to the wake signal transmitted through the isolator; and thereafter d) disabling the transmission by deassertion of the wake signal at the host.

Abstract: A battery pack dehumidifier system for controlling the relative humidity within a battery pack enclosure is provided, the dehumidifier system including a desiccant that absorbs/adsorbs water vapor from the battery pack enclosure. The system heats and reactivates the desiccant at predetermined time intervals or when the humidity within the system reaches a preset level, thereby allowing the desiccant to regain its potential for absorbing/adsorbing water vapor.

Abstract: A high voltage (HV) interface housing is provided that includes an assembly of levers within the housing that detect whether or not the HV lines are coupled to the interface housing. If the HV lines are not in place, the lever assembly prevents the interface cover from being fully installed onto the interface housing, thereby preventing the HV interlock loop switch from being closed. As a result, when the HV cables are not in place, the HV interlock loop switch prevents power from being applied to the HV circuit. If, however, the HV lines are properly positioned within the interface housing, the levers of the lever assembly automatically retract, thus allowing the interface cover to be fully installed onto the interface housing. In this state, the interface cover closes the HV interlock loop switch, thus closing the HV interlock loop and allowing power to be applied to the HV circuit.

Abstract: An integrated drive system assembly is provided that combines an electric motor, a power inverter assembly and a gearbox into a single, multi-piece enclosure. Combining these components into a single enclosure reduces weight, reduces drive system complexity, reduces system volume, simplifies assembly integration into an electric vehicle, reduces manufacturing cost, allows the flexible and lengthy electrical cables between the power inverter and the electric motor to be replaced with short, low loss, rigid bus bars, and simplifies component cooling by allowing the use of a common thermal management system, i.e., a mutual thermal management system. The common thermal management system includes a liquid coolant loop that is thermally coupled to the electric motor, the power inverter assembly and the gearbox.