Abstract: A tab for use in a battery comprises a metal piece that comprises a cross-sectional area geometry that is a rhombus, a parallelogram or a trapezoid when viewed in a lateral direction. The metal piece further comprises a cross-sectional area geometry having a variable thickness when viewed in a longitudinal direction that is perpendicular to the lateral direction. When viewed in the longitudinal direction, a tab thickness t1 at a point where the tab is in contact with an electrode is less than the tab thickness t2 at a point where the tab contacts a pouch.

Abstract: A battery system for a motor vehicle or other system includes a voltage bus with positive and negative bus rails, and first and second battery packs. The battery packs are arranged between and connected to rails. High-voltage switches are collectively configured to selectively interconnect the battery packs in a series or parallel battery arrangement. The switches include a pair of mutually-exclusive three-way/two-position contactors each having a series connection position and parallel connection position corresponding to the respective series and parallel battery arrangements. An electric powertrain includes an electrical load connected to the battery system, and a controller coupled to the switches. In response to a battery mode selection signal, the controller selectively transitions the contactors from the series connection position to the parallel connection position, or vice versa. A motor vehicle includes road wheels, a body, and the electric powertrain.

Abstract: A three-state contactor for an electrical system having a battery pack and voltage bus rail includes first and second pairs of electrical terminals. The first pair of terminals is separated by a first circuit gap in a first circuit path extending between the bus rail and an electrode terminal of the battery pack. The second pair of terminals is separated by a second circuit gap in a second circuit path extending between the bus rail and electrode terminal. A contactor arm, in response to a corresponding switch activation signal, translates in an orthogonal direction with respect to its longitudinal axis between a first ON state position, an OFF position, and a second ON position to close the first circuit gap, open both circuit gaps, or close the second circuit gap, respectively. A multi-pack battery system and an electric powertrain may use the contactor.

Abstract: A battery system includes high-voltage switches, including a multi-pole contactor. Multiple packs are connectable in a series or parallel configuration via the switches. The contactor includes first and second pairs of electrical terminals separated by a respective circuit gap, with respective contactor arms simultaneously closing or opening the gaps. At all times, internal switches formed by the gaps and arms have the same ON/OFF state corresponding to the circuit gaps both being closed or both being open. Two of the contactors may be used to connect the battery packs to a DC fast-charging station, and to connect electrode terminals of the battery packs to a bus rail, respectively. An electric powertrain includes the battery system and an electrical load, including a rotary electric machine, that is connected to a power inverter and to a mechanical load.

Abstract: A lithium-ion electrochemical cell assembly includes a first electrode having a first polarity and a first current collector defining a first electrically conductive tab at an edge of the first electrode. The first electrically conductive tab is substantially covered by a first insulation material. A second electrode has the first polarity and a second current collector defining a second electrically conductive tab at an edge of the second electrode. The second electrically conductive tab is substantially covered by a second insulation material. A weld nugget is formed through at least a portion of the first insulation material and the second insulation material that joins the first electrically conductive tab to the second electrically conductive tab together. Methods of forming lithium-ion electrochemical cells are also provided.

Abstract: A tab for use in a battery comprises a metal piece that comprises a cross-sectional area geometry that is a rhombus, a parallelogram or a trapezoid when viewed in a lateral direction. The metal piece further comprises a cross-sectional area geometry having a variable thickness when viewed in a longitudinal direction that is perpendicular to the lateral direction. When viewed in the longitudinal direction, a tab thickness t1 at a point where the tab is in contact with an electrode is less than the tab thickness t2 at a point where the tab contacts a pouch.

Abstract: A three-state contactor for an electrical system having a battery pack and voltage bus rail includes first and second pairs of electrical terminals. The first pair of terminals is separated by a first circuit gap in a first circuit path extending between the bus rail and an electrode terminal of the battery pack. The second pair of terminals is separated by a second circuit gap in a second circuit path extending between the bus rail and electrode terminal. A contactor arm, in response to a corresponding switch activation signal, translates in an orthogonal direction with respect to its longitudinal axis between a first ON state position, an OFF position, and a second ON position to close the first circuit gap, open both circuit gaps, or close the second circuit gap, respectively. A multi-pack battery system and an electric powertrain may use the contactor.

Abstract: A battery system includes high-voltage switches, including a multi-pole contactor. Multiple packs are connectable in a series or parallel configuration via the switches. The contactor includes first and second pairs of electrical terminals separated by a respective circuit gap, with respective contactor arms simultaneously closing or opening the gaps. At all times, internal switches formed by the gaps and arms have the same ON/OFF state corresponding to the circuit gaps both being closed or both being open. Two of the contactors may be used to connect the battery packs to a DC fast-charging station, and to connect electrode terminals of the battery packs to a bus rail, respectively. An electric powertrain includes the battery system and an electrical load, including a rotary electric machine, that is connected to a power inverter and to a mechanical load.

Abstract: A battery system for a motor vehicle or other system includes a voltage bus with positive and negative bus rails, and first and second battery packs. The battery packs are arranged between and connected to rails. High-voltage switches are collectively configured to selectively interconnect the battery packs in a series or parallel battery arrangement. The switches include a pair of mutually-exclusive three-way/two-position contactors each having a series connection position and parallel connection position corresponding to the respective series and parallel battery arrangements. An electric powertrain includes an electrical load connected to the battery system, and a controller coupled to the switches. In response to a battery mode selection signal, the controller selectively transitions the contactors from the series connection position to the parallel connection position, or vice versa. A motor vehicle includes road wheels, a body, and the electric powertrain.

Abstract: A method according to the present disclosure provides a ground connection between a first component and a vehicle body rail through a coating disposed on the vehicle body rail. The method includes inserting a grounding bushing into an aperture in a second component, positioning the second component between the first component and the vehicle body rail, placing the grounding bushing in contact with the first component, and inserting a fastener through the first component, through the grounding bushing, and into the vehicle body rail. The method further includes tightening the fastener to clamp the first component and the grounding bushing between a head of the fastener and the vehicle body rail and thereby cause the grounding bushing to pierce through the coating disposed on the vehicle body rail to provide the ground connection between the first component and the vehicle body rail.

Abstract: A fastener-holder apparatus is provided. The fastener-holder apparatus includes a fastening member; and a holder member movably connected to the fastening member. The fastener-holder apparatus may be attachable to a vehicle.

Abstract: A method and system for power management among batteries of varying states of health. Two or more battery packs are switched on and off in square wave pulses to energize a multi-winding transformer, and the output of the transformer is used to power a load. As the state of charge of the battery packs decrease at different rates, the duty cycle of each battery pack's switch pulse is made proportional to its state of charge relative to the other battery packs. The battery pack with the greatest state of charge has the longest on-time and provides the most energy to the transformer, yet all battery packs contribute. A baseline duty cycle is computed by a proportional integral control module, based on voltage measurements at the load. Energy contribution is managed so that state of charge does not diverge even when the battery packs have widely varying states of health.

Abstract: Methods and systems for balancing battery states of charge in a multi-sectioned battery. In some embodiments, states of health and states of charge of one or more sections of a multi-sectioned battery may be determined. A relationship between the states of charge and states of health of the battery sections may be determined. This information may be used apply a balancing algorithm to redistribute energy between the various battery sections in order to reduce a spread between the states of charge due to the varying states of health.

Abstract: Methods and systems for balancing battery states of charge in a multi-sectioned battery. In some embodiments, states of health and states of charge of one or more sections of a multi-sectioned battery may be determined. A relationship between the states of charge and states of health of the battery sections may be determined. This information may be used apply a balancing algorithm to redistribute energy between the various battery sections in order to reduce a spread between the states of charge due to the varying states of health.

Abstract: A battery pack having an integrated cooling system which includes a first battery module including a first plurality of battery cells separated by a first plurality of channels, a second battery module including a second plurality of battery cells separated by a second plurality of channels, and a fan that creates air flow between the first and second plurality of channels. The battery pack also includes a manifold having a first conduit section lead from the fan to the first plurality of channels and a second conduit section lead from the fan to the second plurality of channels. Characteristically, the fan is positioned in the manifold where it creates the air flow that is directed by the manifold to the first plurality of channels and the second plurality of channels.

Abstract: A method and system for power management among batteries of varying states of health. Two or more battery packs are switched on and off in square wave pulses to energize a multi-winding transformer, and the output of the transformer is used to power a load. As the state of charge of the battery packs decrease at different rates, the duty cycle of each battery pack's switch pulse is made proportional to its state of charge relative to the other battery packs. The battery pack with the greatest state of charge has the longest on-time and provides the most energy to the transformer, yet all battery packs contribute. A baseline duty cycle is computed by a proportional integral control module, based on voltage measurements at the load. Energy contribution is managed so that state of charge does not diverge even when the battery packs have widely varying states of health.