Abstract: A battery module having first and second battery cells is provided. The battery module includes a first frame member having a first substantially rectangular ring-shaped outer plastic frame and a first heat exchanger. The first heat exchanger has first and second thermally conductive plates that are coupled together and define a first flow path portion extending therethrough. The first battery cell is disposed on and against a first side of the first thermally conductive plate. The second battery cell is disposed on and against the first side of the first thermally conductive plate. The second battery cell is further disposed proximate to the first battery cell.

Abstract: A battery pack has a battery pack housing that defines an interior region, and a battery module that is disposed in the interior region. The battery module has a first battery cell, and a first heat exchanger defining a first flow path portion therethrough. The battery pack further includes a first electric fan and a thermally conductive housing that are disposed in the interior region. The thermally conductive housing has a first housing portion, and at least first and second cooling fins defining a second flow path portion therebetween. At least a portion of the second flow path portion is substantially in-line with the first flow path portion. The first electric fan urges air to flow through an inlet aperture, the first flow path portion, the second flow path portion, and through the first electric fan to a first outlet aperture to cool the battery module.

Abstract: A power control system for adjusting an input power limit of a DC-DC voltage converter is provided. The system includes a microprocessor that determines an amount of output power being output by a battery pack, an amount of available power in the battery pack, and an amount of input power being input to the DC-DC voltage converter. The microprocessor determines an amount of power being provided to the DC-AC inverter based on the amount of output power being output by the battery pack and the amount of input power being input to the DC-DC voltage converter. The microprocessor decreases the input power limit of the DC-DC voltage converter if a sum of the amount of power being provided to the DC-AC inverter and the amount of input power being input to the DC-DC voltage converter is greater than the amount of available power in the battery pack.

Abstract: A battery cell assembly having first, second, and third battery cells and a unitary wrapping sheet is provided. The unitary wrapping sheet is disposed on a top surface and a bottom surface of the first battery cell. The unitary wrapping sheet is further disposed on a top surface and a bottom surface of the second battery cell. The unitary wrapping sheet is further disposed on a top surface and a bottom surface of the third battery cell. The unitary wrapping sheet is further disposed on and encloses a portion of a combined periphery of the first, second, and third battery cells such that the top surface of the first battery cell, the top surface of the second battery cell, and the top surface of the third battery cell are held substantially parallel to one another.

Abstract: A battery pack is provided. The battery pack includes first and second temperature sensors that are disposed in first and second interior spaces, respectively. The first temperature sensor generates a first signal indicative of a first temperature level of the battery cell. The second temperature sensor generates a second signal indicative of a second temperature level of the DC-DC voltage converter. The battery pack further includes a microprocessor that determines a first desired operational speed value of the electric fan based on the first temperature level, and a second desired operational speed value of the electric fan based on the second temperature level. The microprocessor selects the first desired operational speed value if the first desired operational speed value is greater than the second desired operational speed value.

Abstract: A battery pack includes a battery pack housing defining an interior region with first and second interior spaces and an intermediate space. The battery pack housing includes inlet and outlet apertures communicating with the first and second interior spaces, respectively. The battery pack has a battery module disposed in the first interior space having a first battery cell and a heat exchanger. The heat exchanger defines a first flow path portion therethrough. The battery pack has a fan assembly disposed in the intermediate space having a first electric fan, and a thermally conductive housing disposed in the second interior space that defines a second flow path portion. The first electric fan urges air to flow through the inlet aperture, the first flow path portion, a portion of the first electric fan, the second flow path portion, and the outlet aperture.

Abstract: A pre-charging and voltage supply system for a DC-AC inverter is provided. The system includes a first battery having a first anode and a first cathode, and a second battery having a second anode and a second cathode. The first cathode is electrically isolated from the second cathode. The system includes a contactor coupled in series between the first anode and an electrical node. The system includes a microprocessor that generates a first control signal to induce a DC-DC voltage converter to increase a voltage level applied to the DC-AC inverter. The microprocessor generates a second control signal to induce the contactor transition to a closed position such that a first voltage level is applied to the DC-AC inverter, if the voltage level between the electrical node and the first cathode is greater than a threshold voltage level.

Abstract: A battery pack is provided. The battery pack includes first and second temperature sensors that are disposed in first and second interior spaces, respectively. The first temperature sensor generates a first signal indicative of a first temperature level of the battery cell. The second temperature sensor generates a second signal indicative of a second temperature level of the DC-DC voltage converter. The battery pack further includes a microprocessor that determines a first fan speed percentage value of the electric fan based on the first temperature level, and a second fan speed percentage value of the electric fan based on the second temperature level. The microprocessor selects the first fan speed percentage value if the first fan speed percentage value is greater than the second fan speed percentage value.

Abstract: A battery pack has a battery pack housing that defines an interior region, and a battery module that is disposed in the interior region. The battery module has a first battery cell, and a first heat exchanger defining a first flow path portion therethrough. The battery pack further includes a first electric fan and a thermally conductive housing that are disposed in the interior region. The thermally conductive housing has a first housing portion, and at least first and second cooling fins defining a second flow path portion therebetween. At least a portion of the second flow path portion is substantially in-line with the first flow path portion. The first electric fan urges air to flow through an inlet aperture, the first flow path portion, the second flow path portion, and through the first electric fan to a first outlet aperture to cool the battery module.

Abstract: A battery cell assembly having first, second, and third battery cells and a unitary wrapping sheet is provided. The unitary wrapping sheet is disposed on a top surface and a bottom surface of the first battery cell. The unitary wrapping sheet is further disposed on a top surface and a bottom surface of the second battery cell. The unitary wrapping sheet is further disposed on a top surface and a bottom surface of the third battery cell. The unitary wrapping sheet is further disposed on and encloses a portion of a combined periphery of the first, second, and third battery cells such that the top surface of the first battery cell, the top surface of the second battery cell, and the top surface of the third battery cell are held substantially parallel to one another.

Abstract: A battery cell interconnect and voltage sensing assembly having a plastic frame member having a plate portion and a central wall is provided. The central wall defines an interior region. The assembly further includes a first interconnect member that is coupled to the plate portion that is electrically coupled to a first electrical terminal of a first battery cell. The first interconnect member has a spade lug. The assembly further includes a removable wire harness assembly having an adaptor body, a spade clip, and an electrical cable. The spade clip is disposed in an aperture of the adapter member. The spade clip is electrically and physically coupled to the spade lug of the first interconnect member when the adapter member is at least partially disposed in the interior region.

Abstract: A voltage supply system having a first battery with a first anode and a first cathode, and a contactor coupled in series between the first anode and an electrical node is provided. The system includes a first voltage sensor generating a signal indicative of a first voltage level of the first battery, and a second voltage sensor generating a signal indicative of a second voltage level between the electrical node and the first cathode. The system includes a DC-DC voltage converter coupled between the electrical node and the first cathode; and a second battery, and a microprocessor. The microprocessor disables operation of the DC-DC voltage converter such that the converter does not apply a voltage to the second battery, if both the first voltage level is substantially equal to the second voltage level, and the first voltage level is less than a first threshold voltage level.

Abstract: A battery pack includes a battery pack housing defining an interior region with first and second interior spaces and an intermediate space. The battery pack housing includes inlet and outlet apertures communicating with the first and second interior spaces, respectively. The battery pack has a battery module disposed in the first interior space having a first battery cell and a heat exchanger. The heat exchanger defines a first flow path portion therethrough. The battery pack has a fan assembly disposed in the intermediate space having a first electric fan, and a thermally conductive housing disposed in the second interior space that defines a second flow path portion. The first electric fan urges air to flow through the inlet aperture, the first flow path portion, a portion of the first electric fan, the second flow path portion, and the outlet aperture.

Abstract: A battery cell assembly having first and second rectangular-shaped end plates, a battery cell, and a metal spring clip are provided. The first rectangular-shaped end plate includes first and second grooves, and the second rectangular-shaped end plate includes first and second grooves. The battery cell is disposed between the first and second rectangular-shaped end plates. The metal spring clip has first and second end portions. The first end portion is disposed in the first groove of the first rectangular-shaped end plate, and the second end portion is disposed in the first groove of the second substantially rectangular-shaped end plate to bias the first rectangular-shaped end plate toward the second rectangular-shaped end plate.

Abstract: A pre-charging and voltage supply system for a DC-AC inverter is provided. The system includes a first battery having a first anode and a first cathode, and a second battery having a second anode and a second cathode. The system further includes a contactor electrically coupled in series between the first anode and an electrical node. The system further includes a microprocessor that generates a first control signal to induce a DC-DC voltage converter to increase a voltage level between the electrical node and the first cathode. The microprocessor further generates a second control signal to induce the contactor to transition a contact to a closed operational position such that a first voltage level is applied to the DC-AC inverter, if the voltage level between the electrical node and the first cathode is greater than a threshold voltage level.

Abstract: An electrical connector includes a first terminal assembly having a first pin assembly with a first plurality of pins and a second plurality of pins is provided. The electrical connector includes a first end cap attached to the first terminal assembly to urge a first electrical terminal against the first plurality of pins such that the first plurality of pins extend through and contact the first electrical terminal. The electrical connector includes a second terminal assembly having a first pin assembly with a first plurality of female pins and a second plurality of pins. The electrical connector includes a second end cap attached to the second terminal assembly to urge a second electrical terminal against the second plurality of pins of the first pin assembly of the second terminal assembly such that the second plurality of pins of the first pin assembly of the second terminal assembly extend through and contact the second electrical terminal.

Abstract: An electrical connector includes a first terminal assembly having a first pin assembly with a first plurality of pins and a second plurality of pins is provided. The electrical connector includes a first end cap attached to the first terminal assembly to urge a first electrical terminal against the first plurality of pins such that the first plurality of pins extend through and contact the first electrical terminal. The electrical connector includes a second terminal assembly having a first pin assembly with a first plurality of female pins and a second plurality of pins. The electrical connector includes a second end cap attached to the second terminal assembly to urge a second electrical terminal against the second plurality of pins of the first pin assembly of the second terminal assembly such that the second plurality of pins of the first pin assembly of the second terminal assembly extend through and contact the second electrical terminal.

Abstract: A battery cell assembly having first and second rectangular-shaped end plates, a battery cell, and a metal spring clip are provided. The first rectangular-shaped end plate includes first and second grooves, and the second rectangular-shaped end plate includes first and second grooves. The battery cell is disposed between the first and second rectangular-shaped end plates. The metal spring clip has first and second end portions. The first end portion is disposed in the first groove of the first rectangular-shaped end plate, and the second end portion is disposed in the first groove of the second substantially rectangular-shaped end plate to bias the first rectangular-shaped end plate toward the second rectangular-shaped end plate.

Abstract: A battery pack is provided. The battery pack includes first and second temperature sensors that are disposed in first and second interior spaces, respectively. The first temperature sensor generates a first signal indicative of a first temperature level of the battery cell. The second temperature sensor generates a second signal indicative of a second temperature level of the DC-DC voltage converter. The battery pack further includes a microprocessor that determines a first fan speed percentage value of the electric fan based on the first temperature level, and a second fan speed percentage value of the electric fan based on the second temperature level. The microprocessor selects the first fan speed percentage value if the first fan speed percentage value is greater than the second fan speed percentage value.

Abstract: An electrical connector includes a first terminal assembly having a first pin assembly with a first plurality of pins and a second plurality of pins is provided. The electrical connector includes a first end cap attached to the first terminal assembly to urge a first electrical terminal against the first plurality of pins such that the first plurality of pins extend through and contact the first electrical terminal. The electrical connector includes a second terminal assembly having a first pin assembly with a first plurality of female pins and a second plurality of pins. The electrical connector includes a second end cap attached to the second terminal assembly to urge a second electrical terminal against the second plurality of pins of the first pin assembly of the second terminal assembly such that the second plurality of pins of the first pin assembly of the second terminal assembly extend through and contact the second electrical terminal.