Abstract: A kilowatt-scale high-frequency electrical power conversion system adapted for variable output power delivery is described, in which switching frequency of switchable power delivery circuitry is dynamically modulated in transition of the system to a low power regime that is substantially below maximum power output, in order to at least partially attenuate thermal overload from heat generation of switching components in such transitions. The system is useful in high-efficiency charging of rechargeable batteries of electrical vehicles, e.g., e.g., automotive, industrial, and other motive power vehicles.

Abstract: A kilowatt-scale high-frequency electrical power conversion system adapted for variable output power delivery is described, in which switching frequency of switchable power delivery circuitry is dynamically modulated in transition of the system to a low power regime that is substantially below maximum power output, in order to at least partially attenuate thermal overload from heat generation of switching components in such transitions. The system is useful in high-efficiency charging of rechargeable batteries of electrical vehicles, e.g., e.g., automotive, industrial, and other motive power vehicles.

Abstract: A thermal management system for fast charging and subsequent heavy use operation of high-capacity batteries. The thermal management system includes at least one motive driver arranged to impinge air on the terminal and strap structure of the high capacity battery. The terminal and strap structure in a specific aspect of the invention is protectively shrouded by a cover including a main top surface member having air inflow openings therein and a circumscribing wall depending downwardly therefrom and provided with gas egress openings along its medial and end portions. Such cover allows a high flux flow of air therethrough, for high efficiency cooling of the battery during fast charging and subsequent heavy use operation.

Abstract: A high capacity battery including terminals on a terminal-bearing face thereof, and a plate member coupled in spaced-apart relationship to the terminal-bearing face to define a coolant gas flow space therebetween including a peripheral gap for coolant gas communication with an exterior environment of the battery. One or more motive coolant gas drivers is mounted on the plate member and arranged for effecting flow of coolant gas through the coolant gas flow space and the peripheral gap, and the motive coolant gas drivers are electrically coupled with the terminal-bearing face for powering of such drivers. Such high capacity battery can be substituted for a conventional battery in a battery-powered apparatus such as a forklift vehicle, to provide extended use operation as a result of the on-board thermal management capability of the battery.

Abstract: A highly efficient fast charger for high capacity batteries and methods for fast charging high capacity batteries. The fast charger preferably comprises a rectified AC input of single or preferably three phases, with an optional power factor corrected input, minimally filtered with high frequency, high ripple current capacitors, which is switched with a power switching circuit in the “buck” configuration into an inductor/capacitor output filter. Metallized film capacitors are employed, to minimize the rectified 360 Hertz AC component filtering while providing transient switch protection and ripple current requirements for the buck regulator, to provide a high current fast charger with substantially improved power factor. High power, high frequency switching with minimized output filter size provides a highly filtered DC output. The fast charger is adapted to be constructed in a modular design for simple maintenance.

Abstract: A highly efficient fast charger for high capacity batteries and methods for fast charging high capacity batteries. The fast charger preferably comprises a rectified AC input of single or preferably three phases, with an optional power factor corrected input, minimally filtered with high frequency, high ripple current capacitors, which is switched with a power switching circuit in the “buck” configuration into an inductor/capacitor output filter. Metallized film capacitors are employed, to minimize the rectified 360 Hertz AC component filtering while providing transient switch protection and ripple current requirements for the buck regulator, to provide a high current fast charger with substantially improved power factor. High power, high frequency switching with minimized output filter size provides a highly filtered DC output. The fast charger is adapted to be constructed in a modular design for simple maintenance.