Abstract: A method of handling a fault in a battery pack, the method comprising: a battery module supplying a voltage to a high-voltage circuit; a battery management system transmitting a heartbeat signal to the battery module via a fault bus; the battery module preventing the heartbeat signal from being transmitted back to the battery management system in response to the battery module detecting a critical condition; and the battery management system shutting off the supply of voltage from the battery module to the high-voltage circuit in response to the battery module preventing the heartbeat signal from being transmitted back to the battery management system. The battery module transmits battery data to the battery management system via a communication bus, which is distinct from the fault bus, and the battery management system transmits one or more commands to the battery module via the communication bus.

Abstract: Methods of fabricating the fusible link are directed to processing a multi-layer clad foil having a first layer suitable for forming a fusible link and a second layer suitable for forming one or more welding tabs. In some embodiments, the first layer is an aluminum layer and the second layer is a nickel layer. A two-step etching process or a single step etching process is performed on the clad foil to form an etched clad foil having multiple tabs made of the second layer and connected to the current collector conductor pads and battery cell conductor pads, and one or more connections made of the first layer that form aluminum conductors. The aluminum conductors are shaped and sized to form aluminum fusible conductors during either the etching process or a subsequent stamping process. A single fusible link or an array of fusible links can be formed.

Abstract: A fusible link includes a current collector element, a battery cell conductor pad, and at least one fusible conductor connecting the current collector element and the battery cell conductor pad. The current collector element can be a current collector conductor pad, a current collector conductor pad and a current collector plate, or a fuse sheet. A battery cell has an anode electrode and a cathode electrode, a separate fusible link is coupled to at least one of the battery cell electrodes. The battery cell conductor pad is electrically and mechanically attached to each battery cell electrode. The fusible conductor opens under excessive current flow, and has sufficient service loop length to allow relative in-plane and out-of-plane motions between the battery cell electrode and the current collector element. The fusible links can be applied to each of a plurality of battery cells included in a battery pack.

Abstract: A system for charging a battery pack of an electric vehicle comprises a heater for pre-heating the battery pack so that the battery pack is able to accept a charge from a charger. The battery pack is selectively de-coupled from the system during the pre-heating. When the battery pack has reached an appropriate temperature, the heater is selectively de-coupled from the system and the charger is coupled to the system to charge the battery. Advantageously, the battery pack is protected during pre-heating.

Abstract: A method of registering a plurality of Battery-Monitoring-Units (BMUs) in a battery pack with a Battery-Management-System (BMS), the method comprising: providing an indication to a user, wherein the indication prompts the user to register one of the BMUs with the BMS; the user performing an action on a communication-initiating mechanism on one of the BMUs, wherein the communication-initiating mechanism is configured to initiate the sending of a communication by the BMU to the BMS in response to the user performing the action; the BMU sending a communication to the BMS in response to the user performing the action on the communication-initiating mechanism; the BMS receiving the communication from the BMU; and the BMS registering the BMU in response to receiving the communication from the BMU.

Abstract: Faulty battery detecting and locating devices and methods are able to detect and locate a faulty battery cell. The device applies an energy to a sensing member, such as a polymeric tube containing at least two polymer-coated and twisted electric wires. Heat that is generated by a faulty battery triggers an electric communication between the two electric wires by melting at least a portion of the polymer. The resulting change in resistance between the two electric wires is used to detect and locate a faulty battery.

Abstract: A motor comprises a stator having open slots with a double layer formed coil lapped winding and the method to manufacture thereof.

Abstract: Methods of fabricating the fusible link are directed to processing a multi-layer clad foil having a first layer suitable for forming a fusible link and a second layer suitable for forming one or more welding pads. In some embodiments, the first layer is an aluminum layer and the second layer is a nickel layer. A two-step etching process or a single step etching process is performed on the clad foil to form an etched clad foil having multiple tabs made of the second layer used as current collector conductor pads and battery cell conductor pads, and one or more tabs made of the first layer that form aluminum conductors. The aluminum conductors are shaped and sized to form aluminum fusible conductors during either the etching process or a subsequent stamping process. A single fusible link or an array of fusible links can be formed.

Abstract: A battery liquid temperature regulating device includes one or more battery cells thermally coupled to one or more temperature regulating modules. A first temperature regulating module is thermally coupled to one end of each battery cell, and in some embodiments, a second temperature regulating module is thermally coupled to the other end of each battery cell. Each temperature regulating module is configured with one or more channels. Heat is transferred between each battery cell end, the material of the temperature regulating module, and the liquid flowing through the one or more channels. The temperature regulating modules are also thermally coupled to current collecting elements electrically coupled to the battery cell to similarly transfer heat between these elements.

Abstract: Faulty battery detecting and locating devices and methods are able to detect and locate a faulty battery cell. The device applies an energy to a sensing member, such as a polymeric tube containing at least two polymer-coated and twisted electric wires. Heat that is generated by a faulty battery triggers an electric communication between the two electric wires by melting at least a portion of the polymer. The resulting change in resistance between the two electric wires is used to detect and locate a faulty battery.

Abstract: Methods of fabricating the fusible link are directed to processing a multi-layer clad foil having a first layer suitable for forming a fusible link and a second layer suitable for forming one or more welding pads. In some embodiments, the first layer is an aluminum layer and the second layer is a nickel layer. A two-step etching process or a single step etching process is performed on the clad foil to form an etched clad foil having multiple tabs made of the second layer used as current collector conductor pads and battery cell conductor pads, and one or more tabs made of the first layer that form aluminum conductors. The aluminum conductors are shaped and sized to form aluminum fusible conductors during either the etching process or a subsequent stamping process. A single fusible link or an array of fusible links can be formed.

Abstract: An apparatus for detecting change in orientation comprises a first position sensor and a second position sensor. The position sensors are in different orientations. The outputs of the position sensors are filtered to smooth out instantaneous and/or insignificant changes in orientation, or noise. A processor or logic circuitry is configured to determine a change in both outputs, and communicate such a change. Furthermore, the processor or logic circuitry is configured to electrically and/or physically de-couple batteries from a power delivery system in an EV.

Abstract: A method of handling a fault in a battery pack, the method comprising: a battery module supplying a voltage to a high-voltage circuit; a battery management system transmitting a heartbeat signal to the battery module via a fault bus; the battery module preventing the heartbeat signal from being transmitted back to the battery management system in response to the battery module detecting a critical condition; and the battery management system shutting off the supply of voltage from the battery module to the high-voltage circuit in response to the battery module preventing the heartbeat signal from being transmitted back to the battery management system. The battery module transmits battery data to the battery management system via a communication bus, which is distinct from the fault bus, and the battery management system transmits one or more commands to the battery module via the communication bus.

Abstract: A method of registering a plurality of Battery-Monitoring-Units (BMUs) in a battery pack with a Battery-Management-System (BMS), the method comprising: providing an indication to a user, wherein the indication prompts the user to register one of the BMUs with the BMS; the user performing an action on a communication-initiating mechanism on one of the BMUs, wherein the communication-initiating mechanism is configured to initiate the sending of a communication by the BMU to the BMS in response to the user performing the action; the BMU sending a communication to the BMS in response to the user performing the action on the communication-initiating mechanism; the BMS receiving the communication from the BMU; and the BMS registering the BMU in response to receiving the communication from the BMU.

Abstract: A system for charging a battery pack of an electric vehicle comprises a heater for pre-heating the battery pack so that the battery pack is able to accept a charge from a charger. The battery pack is selectively de-coupled from the system during the pre-heating. When the battery pack has reached an appropriate temperature, the heater is selectively de-coupled from the system and the charger is coupled to the system to charge the battery. Advantageously, the battery pack is protected during pre-heating.

Abstract: A movable, portable, and instantly attachable/detachable battery pack includes batteries enclosed in a case with a ground transportation structure, such as wheels, coasters, and runners. The battery pack can include handles and mating connectors. The ground transportation structure allows the majority of the weight of the battery packs to be supported by the ground during transportation. The person who moves the battery pack only needs to use a minimum force sufficient to move the battery pack in a direction perpendicular to the force of gravity. Battery packs disclosed herein can be easily maneuvered into a building or structures to be recharged or swapped.

Abstract: A fusible link includes a current collector element, a battery cell conductor pad, and at least one fusible conductor connecting the current collector element and the battery cell conductor pad. The current collector element can be a current collector conductor pad, a current collector conductor pad and a current collector plate, or a fuse sheet. A battery cell has an anode electrode and a cathode electrode, a separate fusible link is coupled to at least one of the battery cell electrodes. The battery cell conductor pad is electrically and mechanically attached to each battery cell electrode. The fusible conductor opens under excessive current flow, and has sufficient service loop length to allow relative in-plane and out-of-plane motions between the battery cell electrode and the current collector element. The fusible links can be applied to each of a plurality of battery cells included in a battery pack.

Abstract: A power delivery system in an electric vehicle comprises a connection backplane configured to receive a plurality of modular batteries. The connection backplane operates to route power, status and control signals between a modular battery back, a controller, and a powertrain. A method of operating an EV comprises determining a route for an EV and an amount of energy required to complete the route. The method further comprises coupling an appropriate number of batteries to a connection backplane, wherein the batteries have sufficient energy to power the EV for the duration of the route.

Abstract: A battery pack heat exchanger, system, and method comprises a plurality of battery modules comprising a heat exchanger having an outer shell and a plurality of cylinders extending within the outer shell. A plurality of battery cells are positioned within the plurality of cylinders and a coolant is poured into the shell via a fill port. As a result, the coolant is able to absorb and dissipate localized heat produced by the battery cells throughout the heat exchanger. Therefore, if one battery cell undergoes a thermal run-away, the heat will be distributed throughout the shell volume thereby greatly reducing the likelihood that battery cells directly adjacent the run-away cell absorb the brunt of the heat and undergo thermal run-away themselves.