Abstract: A battery control system for an electric vehicle including a battery pack includes a dew point calculation module that receives at least a first signal indicative of humidity within the battery pack and a second signal indicative of temperature within the battery pack, and that calculates a dew point within the battery pack based on the humidity and the temperature. A coolant system control module receives the dew point and a requested coolant temperature, sets a desired coolant temperature based on the dew point and the requested coolant temperature, and selectively operates a coolant system of the battery pack based on the desired coolant temperature.

Abstract: A battery disconnect unit (BDU) is arranged to selectively enable current flow between a power source and a battery pack of a vehicle, and between the battery pack and the vehicle. The battery disconnect unit includes a housing having an exterior and an interior, a first exterior surface and a first interior surface, and an opening opposite the first interior surface. A plurality of BDU components are mounted within the interior of the housing. The BDU components are mounted at least one of on and adjacent to the first interior surface of the housing, and respective fasteners used to mount the BDU components to the first interior surface of the housing are not exposed on the first exterior surface of the housing. When the housing is mounted on a mounting surface associated with the battery pack, the opening is arranged adjacent to the mounting surface and the first interior surface is arranged opposite the mounting surface relative to the opening.

Abstract: A lithium ion cell includes a housing and positive and negative terminals. The housing includes top and bottom surfaces. The housing includes first, second, third, and fourth side surfaces, perpendicular to the top and bottom surfaces. A cell isolator includes first and second portions made of an electrically non-conductive material. The first portion includes first, second, and third wall members. The first wall member directly contacts the first side surface. The second wall member directly contacts a portion of the second side surface. The third wall member directly contacts a portion of the third side surface. The second portion includes fourth, fifth, and sixth wall members. The fourth wall member directly contacts the fourth side surface. The fifth wall member directly contacts portions of the second side surface and the second wall member. The sixth wall directly contacts portions of the third side surface and the third wall member.

Abstract: A battery module for enclosing at least one battery cell includes a cooling plate. At least one compressible pad is arranged on the cooling plate. The at least one compressible pad has a first surface in contact with the cooling plate and a second surface opposite the first surface arranged to contact the at least one battery cell. A compression limiting device is arranged adjacent to the at least one compressible pad. The compression limiting device has a first surface facing the cooling plate and a second surface opposite the first surface arranged to contact the at least one battery cell. A compressibility of the compression limiting device is less than a compressibility of the at least one compressible pad.

Abstract: A system includes a battery control module that determines at least one temperature associated with a battery pack of an electric vehicle. An electric vehicle control module selects between a plurality of operating modes of the electric vehicle based on the at least one temperature. The plurality of operating modes includes a first mode and a second mode. In the first mode the electric vehicle control module prevents the electric vehicle from being turned on. In second mode the electric vehicle control module allows the electric vehicle to be turned on in response to a determination that the battery pack has sufficient energy to adjust the at least one temperature a predetermined amount and to drive the vehicle a predetermined distance.

Abstract: A battery module according to the principles of the present disclosure includes a plurality of battery cells, a pair of sideplates, and a pair of endplates. The sideplates are disposed on opposite sides of the plurality of battery cells and the endplates are disposed at opposite ends of the battery module. The sideplates include a first mating portion and the endplates include a second mating portion that engages the first mating portion to provide an interference fit. The interference fit joins the sideplates and the endplates together and bands the plurality of cells together between the sideplates and the endplates.

Abstract: A method includes: generating a first age factor value for a battery based on: a cycle period of the battery; a required operational life of the battery; and a cycle life of the battery. The method further includes generating a second age factor value for the battery based on: the required operational life; and a resting life of the battery. The method further includes generating a third age factor value for the battery based on: the required operational life; the first age factor value; the second age factor value; and at least one of an expected period of cycling of the battery during the required operational life and expected period of resting of the battery during the required operational life. The method further includes: generating an expected life of the battery based on the required operational life and the third age factor value; and displaying the expected life.

Abstract: Disclosed herein is a multi-cell battery pack having optimal temperature distribution throughout the battery pack and optimal air flow through the battery pack. Disclosed herein is a battery pack which provides optimal temperature distribution throughout the battery pack, wherein maximum cell temperature (Tmax) and temperature differential amongst all cells in the battery pack (?Tcell) are optimized for efficient thermal management providing safety, improved performance and extended life of the battery pack and electrochemical cells. Also disclosed herein is a battery pack which provides optimal flow through the battery pack and minimal pressure drop (?P) throughout the battery pack.

Abstract: A battery pack for an electric vehicle includes a first battery, a second battery, and a load arranged in parallel. A first semiconductor switching module is arranged in series with the first battery, and to selectively allow current flow from the first battery to the load and from the load to the first battery. A second semiconductor switching module is arranged in series with the second battery, and to selectively allow current flow from the second battery to the load and from the load to the second battery. A battery control module stores at least one of charge data and usage data corresponding to the first battery and the second battery, and selectively turns on and off the first semiconductor switching module and the second semiconductor switching module based on at least one of the charge data and the usage data.

Abstract: A battery pack for an electric vehicle includes a first battery arranged in parallel with a load of the electric vehicle. A second battery is arranged in parallel with the first battery and the load. A first semiconductor switching module is arranged in series with the first battery and is arranged to selectively allow current flow from the first battery to the load and from the load to the first battery. A second semiconductor switching module is arranged in series with the second battery and is arranged to selectively allow current flow from the second battery to the load and from the load to the second battery. A battery control module selectively turns on and off the first semiconductor switching module and the second semiconductor switching module.

Abstract: A system according to the principles of the present disclosure includes a battery disconnect unit (BDU) and a cartridge. The BDU includes a first positive terminal, a first negative terminal, a second positive terminal, a second negative terminal, a first current path, a second current path, a first switch, and a second switch. The first current path is between the first positive terminal and the second positive terminal. The second current path is between the first negative terminal and the second negative terminal. The first switch is disposed in the first current path. The second switch is disposed in the second current path. The cartridge includes a first terminal, a second terminal, and a current path between the first terminal and the second terminal. The first terminal is configured to connect to one of the terminals on the BDU.

Abstract: A first battery includes a first and terminals having first and second reference potentials, respectively. A second battery includes a third and fourth terminals having a third and fourth reference potentials, respectively. A bus bar comprises: a first terminal contactor portion that is electrically conductive and that directly contacts one of the first and second terminals of the first battery; a second terminal contactor portion that is electrically conductive and that directly contacts one of the third and fourth terminals of the second battery; and a connecting portion that is electrically conductive, that is electrically connected between the first terminal contactor portion and the second terminal contactor portion, and that creates an open circuit between the first and second terminal contactor portions in response to current flow through the connecting portion that is greater than a predetermined current for at least a predetermined period.

Abstract: A system includes a plurality of batteries, first and second relays, a relay control module, and a welding indication module. The batteries are electrically connected and collectively output power for an electric motor via first and second nodes. The first relay is connected between a first output of the batteries and the first node. The second relay is connected between a second output of the batteries and the second node. The relay control module controls the first and second relays. The welding indication module commands the relay control module to open the first relay during a diagnosis period, commands the relay control module to close the second relay during the diagnosis period, and indicates whether the first relay is welded closed based on a voltage between the first and second nodes during the diagnosis period.

Abstract: A battery cell according to the principles of the present disclosure includes a cell housing and a mounting member that is fixed to an outer surface of the cell housing. In one example, the mounting member is formed separate from the cell housing and attached to the outer surface of the cell housing. In another example, the mounting member is unitarily formed with the cell housing and protrudes from a planar surface of the cell housing.

Abstract: A battery assembly includes a housing and N charge storage devices within the housing. The system also includes a first tray includes a first side that includes X areas that transfer first current from electrolyte leaked from a first one of the N charge storage devices to a current detector. The tray includes a second side that insulates the housing from the electrolyte. N and X are integers greater than or equal to 1.

Abstract: Disclosed herein is a modular battery system having at least one subsystem comprising a plurality of battery modules connected in series or parallel, wherein each subsystem preferably having a first endplate and a second endplate. The battery modules may be bound between the first and second endplates. A plurality of band members couple the first and second endplates to each other and bind the battery module between the endplates. Further, a data collection panel is in electrical communication with each of the battery modules and the data collection panel transmits status information of the modules to a master control module, which converts the electrical into a data transmission through a controller area network (CAN) bus. Status information may include module temperature, module pressure and module voltage, essentially any measurable parameter that may be conducted via an electrical signal. Depending on the needs of a given application, the battery modules may be connected in series or parallel.

Abstract: A battery pack according to the present disclosure includes a first module array, a second module array, and a center channel. The first module array includes a first frame and a first cassette of battery modules disposed within the first frame. The first cassette of battery modules includes a first plurality of prismatic cells and a first plurality of module terminals. The second module array includes a second frame and a second cassette of battery modules disposed within the second frame. The second cassette of battery modules includes a second plurality of prismatic cells and a second plurality of module terminals. The center channel extends through a center of the battery pack and connects the first module array to the second module array. The first plurality of module terminals and the second plurality of module terminals are disposed adjacent to the center channel on opposite sides of the center channel.

Abstract: A modular frame for a battery module includes: a floor that includes an electrically non-conductive material; end walls that are perpendicular to the floor and that include the electrically non-conductive material; and side walls that are perpendicular to the floor, that are perpendicular to the end walls, and that include the electrically non-conductive material. The modular frame further includes interior walls that include the electrically non-conductive material and that define: a first row of cell slots configured to receive a first plurality of prismatic cells; a second row of cell slots configured to receive a second plurality of prismatic cells; and a chamber disposed between the first and second rows of cell slots. The modular frame further includes a first and second apertures to the chamber. The first aperture is defined by the interior walls and the side walls. The second aperture is formed through one of the end walls.

Abstract: A battery pack includes a frame member, first and second lithium ion cells, and an isolation plate. The frame member includes a floor, walls formed perpendicular to the floor, and an aperture defined by the walls. The frame member is formed from an electrically non-conductive plastic. The first lithium ion cell includes a first positive terminal, a first negative terminal, and a first electrically conductive housing. The first positive terminal is electrically connected to the first electrically conductive housing. The second lithium ion cell includes a second positive terminal, a second negative terminal, and a second electrically conductive housing. The second positive terminal is electrically connected to the second electrically conductive housing. The isolation plate directly contacts both the first and second electrically conductive housings and electrically isolates the first electrically conductive housing from the second electrically conductive housing.

Abstract: A modular frame includes a first row of cell slots configured to receive first prismatic cells of a battery pack system. A second row of cell slots is configured to receive second prismatic cells of the battery pack system. A central interface beam is disposed between the first row of cell slots and the second row of cell slots. The central interface beam includes a first side and a second side. The first side is configured to receive terminals of the first prismatic cells. The second side opposes the first side and is configured to receive terminals of the second prismatic cells.