Abstract: A system for integrating the venting feature of a battery with a means for simultaneously disconnecting the cell from the battery pack, thereby isolating the cell, is provided. The provided battery interconnect system is comprised of a battery, a connector plate for electrically coupling the battery to a battery pack, and an interruptible electrical connector for electrically coupling the connector plate to a battery terminal vent. The vent, defined by scoring on the battery terminal, ruptures when the internal battery pressure exceeds the predefined battery operating range, causing the interruptible electrical connector to break and disrupt electrical continuity between the connector plate and the battery terminal.

Abstract: A method and apparatus is provided for determining when a battery, or one or more batteries within a battery pack, undergoes an undesired thermal event such as thermal runaway. The system uses a conductive member mounted in close proximity to, or in contact with, an external surface of the battery or batteries to be monitored. A resistance measuring system such as a continuity-tester or an ohmmeter is coupled to the conductive member, the resistance measuring system outputting a first signal when the temperature corresponding to the battery or batteries is within a prescribed temperature range and a second signal when the temperature exceeds a predetermined temperature that falls outside of the prescribed temperature range.

Abstract: A battery pack thermal management system is provided that is comprised of at least one enclosure failure port integrated into at least one wall of a battery pack enclosure, where the enclosure failure port(s) remains closed during normal operation of the battery pack, and opens during a battery pack thermal runaway event, thereby providing a flow path for hot gas generated during the thermal runaway event to be exhausted out of the battery pack enclosure in a controlled fashion.

Abstract: A motor winding arrangement that is capable of delivering relatively flat torque over a wide range of speeds, thus achieving increasing power throughout its operating range, is provided. In a multi-phase, e.g., three-phase, motor utilizing the winding arrangement of the invention, each winding layer corresponds to one phase of the motor and occupies every slot of the stator. The poles for each winding layer are comprised of concentric and non-overlapping coils.

Abstract: A method and apparatus for optimizing the torque applied by each motor of a dual motor drive system of an all-electric vehicle is provided, the torque adjustments taking into account wheel slip as well as other vehicular operating conditions.

Abstract: A method and apparatus for limiting the adverse effects of temperature on the electrical energy storage system (ESS) of an electric vehicle after the vehicle has been turned off are provided. In general, whether or not coolant is circulated through a coolant loop coupled to the ESS depends on the difference between the ambient temperature and a preset temperature, the preset temperature typically corresponding to the temperature of the ESS.

Abstract: A method and apparatus for actively cooling the battery pack of an electric vehicle after the vehicle has been turned off, thereby limiting the adverse effects of temperature on battery life, are provided. Different battery pack cooling techniques are provided, thus allowing the cooling technique used in a particular instance to be selected not only based on the thermal needs of the battery pack, but also on the thermal capacity and energy requirements of the selected approach.

Abstract: A method and apparatus for an all-electric vehicle using a primary drive system and a secondary drive system is provided. While the primary drive system utilizes a single electric motor, the secondary drive system utilizes a pair of electric motors. In one configuration, a single electrical energy storage system (ESS) is used to supply power to both drive systems. A DC/DC converter can be used so that the two drive systems can utilize different DC bus voltage ranges. In another configuration, each drive system is coupled to a different electrical ESS. A bi-directional DC/DC converter can be used to provide an electrical path between each motor's inverter and the electrical ESS of the other drive system. An energy transfer control module connected to the bi-directional DC/DC converter and one or more sensors can be used to control the use of the bi-directional DC/DC converter.

Abstract: A method and apparatus for an all-electric vehicle using a primary drive system and a secondary drive system is provided. The primary drive system and the secondary drive system each utilize a single electric motor. In one configuration, a single electrical energy storage system (ESS) is used to supply power to both drive systems. A DC/DC converter can be used so that the two drive systems can utilize different DC bus voltage ranges. In another configuration, each drive system is coupled to a different electrical ESS. A bi-directional DC/DC converter can be used to provide an electrical path between each motor's inverter and the electrical ESS of the other drive system. An energy transfer control module connected to the bi-directional DC/DC converter and one or more sensors can be used to control the use of the bi-directional DC/DC converter.

Abstract: A method and apparatus that allows the end user to control the charging system, and in particular the battery pack charging level, of an all-electric or hybrid vehicle based on expected use is provided.

Abstract: One embodiment includes a housing, a first battery cell having a first cell thermal capacitance, the first cell fixedly disposed in the housing, a second battery cell having a second cell thermal capacitance, the second cell fixedly disposed in the housing a minimum air gap away from the first cell, the minimum air gap having an air gap thermal resistance and a heat conductor disposed adjacent each of the cells, with the heat conductor having a heat conductor heat capacitance. A combination of the first cell thermal capacitance, the second cell thermal capacitance, the heat conductor thermal capacitance and the air gap is sufficient to restrict heat flow from the first cell to the second cell during a thermal runaway event of the first cell, the heat flow restricted such that the second cell temperature remains less than a temperature sufficient to cause thermal runaway in the second cell.

Abstract: An induction motor embodiment includes a stator defining a stator bore, the stator including a stator yoke having a stator yoke thickness and a plurality of stator teeth, the teeth having a common length, with each of the stator teeth including a stator tooth center portion that extends from a stator tooth bottom portion proximal the yoke to a stator tooth tip portion, with adjacent stator teeth defining a stator slot between them, each stator slot having a stator slot bottom that extends along a stator slot bottom length. In the embodiment, the center portion has a stator tooth width that is less than or equal to one half the stator slot bottom length. In the embodiment, the stator tooth width is smaller than a stator slot opening width distance. In the embodiment, a ratio of stator yoke thickness to stator tooth width is at least 5:1. A rotor is rotably mounted in the stator.

Abstract: A method for accurately estimating battery capacity based on a weighting function is provided. The disclosed system monitors battery current and uses the monitored battery current to calculate the state of charge (SOCbyAh) of the battery. The system also measures the open circuit voltage (OCV) of the battery when the system is at rest, rest being determined by achieving a current of less than a preset current value for a period of time greater than a preset time period. The state of charge of the battery is calculated from the OCV (SOCbyOCV). The weighting function is based on ?SOCbyAh and ?SOCbyOCV, where ?SOCbyAh is equal to SOCbyAhFirst time minus SOCbyAhSecond time, and where ?SOCbyOCV is equal to SOCbyOCVFirst time minus SOCbyOCVSecond time. The weighting function also takes into account the errors associated with determining SOCbyAh and SOCbyOCV.

Abstract: A simplified cell design is provided for a battery utilizing the 18650 form-factor, the simplified cell design reducing manufacturing cost, battery weight and the risk of shorting between the battery case and the battery terminal. In the cap assembly of the disclosed battery, the safety vent element, which is recessed relative to the top of the cell case, also serves as the battery terminal. Additionally, the insulating gasket positioned between the cell case and the cap assembly is designed to cover a large portion of the outer surface of the safety vent/battery terminal.

Abstract: A system for optimizing battery pack charging is provided. In this system, during charging the coupling of auxiliary systems (e.g., battery cooling systems) to the external power source are delayed so that the battery pack charge rate may be optimized, limited only by the available power. Once surplus power is available, for example as the requirements of the charging system decrease, the auxiliary system or systems may be coupled to the external power source without degrading the performance of the charging system.

Abstract: A battery pack is provided that includes one or more thermal barrier elements, the thermal barrier elements dividing the cells within the battery pack into groups of cells. The thermal barrier elements that separate the cells into groups prevent a thermal runaway event initiated in one group of cells from propagating to the cells within a neighboring group of cells.

Abstract: A simplified cell design is provided for a battery utilizing the 18650 form-factor in which the CID and PTC elements are eliminated, thereby reducing manufacturing cost and battery weight. To reduce the risk of shorting between the battery case and the battery terminal, the battery terminal is recessed relative to the top of the cell case and the insulating gasket positioned between the cell case and the cap assembly is designed to cover a large portion of the outer surface of the terminal element.

Abstract: A method and apparatus for an all-electric vehicle using a primary drive system and a secondary drive system is provided. While the primary drive system utilizes a single electric motor, the secondary drive system utilizes a pair of electric motors. A single electrical energy storage system (ESS) is used to supply power to both drive systems. A DC/DC converter can be used so that the two drive systems can utilize different DC bus voltage ranges.

Abstract: The adverse effects of the dielectric material covering the lateral outer surface of a conventional battery are eliminated by replacing it with a dielectric barrier that covers less than 20 percent of the lateral outer surface of the cell case; more preferably less than 15 percent of the lateral outer surface of the cell case; still more preferably less than 10 percent of the lateral outer surface of the cell case; and yet still more preferably less than 5 percent of the lateral outer surface of the cell case. The dielectric barrier may be shrunk-fit, bonded, friction-fit or otherwise held in place. An electrically insulating disk may be interposed between the dielectric barrier and the end edge portion of the cell case.

Abstract: A method and apparatus is provided in which a layer of an intumescent material surrounds the casing of a battery, the layer helping to prevent the formation of perforations in the battery casing during a thermal runaway event and, if a perforation is formed, inhibiting the flow of hot, pressurized gas from within the battery. A sleeve, surrounding the cell, may be used to contain the intumescent material during the thermal event.

Abstract: A battery is provided in which a thermal insulator or other material is interposed between the electrode assembly and the inner surface of the cell casing, the additional layer(s) inhibiting the formation of wall perforations in the battery casing during a thermal runaway event.

Abstract: A sealed battery enclosure to extend the life of the batteries contained therein is provided, the sealed battery enclosure significantly reducing contamination from water or other liquids and gases.

Abstract: A method and apparatus for simplifying battery pack encapsulation is provided. The battery pack includes a pair of complementary housing members with each housing member including a plurality of cell contraints into which the ends of corresponding battery cells are inserted during assembly. One or both housing members also include at least one, and preferably a plurality, of raised encapsulant injection ports. The raised encapsulant injection ports are designed to extend above the surface of the respective housing members and beyond the injected encapsulation material, thus ensuring that the ports remain open after encapsulation material injection.

Abstract: A method and apparatus is provided for determining when a battery, or one or more batteries within a battery pack, undergoes an undesired thermal event such as thermal runaway. The system uses an insulated conductive member mounted in close proximity to, or in contact with, an external surface of the battery or batteries to be monitored. A voltage measuring system is coupled to the conductive core of the insulated conductive member, the voltage measuring system outputting a first signal when the temperature corresponding to the battery or batteries is within a prescribed temperature range and a second signal when the temperature exceeds a predetermined temperature that falls outside of the prescribed temperature range.

Abstract: A method and apparatus is provided for determining when a battery, or one or more batteries within a battery pack, undergoes an undesired thermal event such as thermal runaway. The system uses an optical fiber mounted in close proximity to, or in contact with, an external surface of the battery or batteries to be monitored. A source of light is optically coupled to the input facet of the optical fiber and a detector optically coupled to the output facet of the optical fiber. Battery health is determined by monitoring the light transmitted through the optical fiber.

Abstract: An active thermal runaway mitigation system is provided that mitigates the effects of a single cell undergoing thermal runaway, thereby preventing the propagation of the thermal runaway event to neighboring cells within the battery pack. The provided system includes at least one, fluid-containing conduit in proximity to the cells within the battery pack. The conduit includes a plurality of breach points in proximity to the subset of cells, where each breach point is configured to form a breach at a preset temperature that is lower than the melting temperature of the conduit. Once a breach is formed, the fluid contained within the conduit is discharged through the breach.

Abstract: A spacer assembly for use with a cell mounting bracket in a battery pack is provided. The spacer assembly, comprised of one or more spacers, maintains the positions of the batteries within the battery pack during a thermal event and after the cell mounting bracket loses structural integrity due to the increased temperature associated with the thermal event. By keeping the battery undergoing thermal runaway in its predetermined location within the battery pack, the minimum spacing between cells is maintained, thereby helping to minimize the thermal effects on adjacent cells while ensuring that the cooling system, if employed, is not compromised. As a result, the risk of thermal runaway propagation is reduced.

Abstract: A system for optimizing battery pack charging is provided. In this system, during charging the coupling of auxiliary systems (e.g., battery cooling systems) to the external power source are delayed so that the battery pack charge rate may be optimized, limited only by the available power. Once surplus power is available, for example as the requirements of the charging system decrease, the auxiliary system or systems may be coupled to the external power source without degrading the performance of the charging system.

Abstract: The adverse effects of the dielectric material covering the cylindrical case of a conventional 18650 cell are eliminated by replacing it with a ring-shaped dielectric material, wherein the ring-shaped dielectric material does not extend down or otherwise cover the cylindrical outer surface of the cell's casing. The ring-shaped dielectric material provides access to the battery terminal corresponding to the cap assembly while preventing shorting between the battery terminal and the edge of the cell casing.

Abstract: A shim coil for use in magnetic resonance imaging spectroscopy (MRIS) is formed by cutting or punching in a sheet of electrically conductive material the required coil pattern. The pattern can be punched using a CNC punching or stamping machine.

Abstract: A liquid cooling manifold assembly for use in the thermal management system of a battery pack is provided. The liquid cooling manifold assembly includes a coolant channel portion through which the coolant channels run, and a dual layer thermal interface interposed between the coolant channel portion and the cells of the battery pack. The outer material layer of the dual layer thermal interface is comprised of an electrically non-conductive, high dielectric material that is preferably tear resistant, deformable and has a high tensile strength and a relatively low surface friction. The inner material layer of the dual layer thermal interface is comprised of a highly compressible material.

Abstract: A motor in an electric vehicle can be controlled by receiving at least one of a user input or vehicle information, selecting one of a plurality of available flux modes using at least one of the user input or the vehicle information, and calculating a control signal, using the selected flux mode, to control the motor of the electric vehicle.

Abstract: A means for inhibiting the propagation of thermal runaway within a plurality of batteries is provided, wherein the means is comprised of a pair of intumescent material layers coating the battery casing, or at least a portion thereof.

Abstract: A means for inhibiting the propagation of thermal runaway within a plurality of batteries is provided, wherein the means is comprised of a layer of intumescent material covering the interior surfaces of the battery pack.

Abstract: A means for inhibiting the propagation of thermal runaway within a plurality of batteries is provided, wherein the means is comprised of at least one layer of intumescent material interposed between the interior surface of the casing of a battery and the corresponding electrode assembly.

Abstract: A system for optimizing battery pack charging is provided. In this system, during charging the coupling of auxiliary systems (e.g., battery cooling systems) to the external power source are delayed so that the battery pack charge rate may be optimized, limited only by the available power. Once surplus power is available, for example as the requirements of the charging system decrease, the auxiliary system or systems may be coupled to the external power source without degrading the performance of the charging system.

Abstract: A method for managing thermal loads within an electric vehicle using an efficient thermal management system (100) that utilizes a single heat exchanger (133) is provided. A refrigeration subsystem (103) cools the heat exchanger (133). A first coolant loop (139) in thermal communication with the heat exchanger (133) is used to cool the energy storage system (137). A second coolant loop (151) corresponding to the HVAC subsystem (107) is also in thermal communication with the heat exchanger (133). Preferably a third coolant loop (109) corresponding to the drive motor cooling subsystem (101) is coupleable to the HVAC coolant loop (151), thus providing an efficient means of providing heat to the HVAC subsystem (107).

Abstract: A lighting control system comprising a plurality of intelligent switches designed to replace a conventional light switch, each of the intelligent switches including a receiver configured to receive communication signals that include rules based instructions for controlling one or more lighting circuits; a circuit interrupter configured to control the amount of current flowing to a lighting circuit; a memory configured to store the rules based instructions; and a processor coupled with the receiver, memory, and circuit interrupter, the processor configured to control the operation of the circuit interrupter based on the rules based instructions stored in memory.

Abstract: One embodiment of the present subject matter includes a system that includes a battery, an electric vehicle, the battery coupled to the electric vehicle to propel the electric vehicle, and a charging circuit to charge the battery. The embodiment includes a charging cost circuit to estimate a charging cost rate and to turn on the charging circuit. The embodiment also includes a timer circuit to provide a time signal to the charging cost circuit. The embodiment is configured such that the charging cost circuit is to turn on the charging circuit during a first time period in which the charging cost rate is below a first threshold until the battery reaches a first energy stored level, and to turn on the charging circuit during a second time period in which the charging cost rate is above the first threshold.

Abstract: One embodiment of the present subject matter includes a system that includes a battery, an electric vehicle, the battery coupled to the electric vehicle to propel the electric vehicle, and a charging circuit to charge the battery. The embodiment includes a charging cost circuit to estimate a charging cost rate and to turn on the charging circuit. The embodiment also includes a timer circuit to provide a time signal to the charging cost circuit. The embodiment is configured such that the charging cost circuit is to turn on the charging circuit during a first time period in which the charging cost rate is below a first threshold until the battery reaches a first energy stored level, and to turn on the charging circuit during a second time period in which the charging cost rate is above the first threshold.

Abstract: A method and apparatus that allows the end user to optimize the performance of an all-electric or hybrid vehicle and its charging system for a desired mode of operation is provided. The system of the invention includes multiple charging/operational modes from which the user may select. Each charging/operational mode controls the cut-off voltage used during charging and the maintenance temperature of the battery pack.

Abstract: A method and apparatus that allows the end user to optimize the performance of an all-electric or hybrid vehicle and its charging system for a desired mode of operation is provided. The system of the invention includes multiple charging/operational modes from which the user may select. Each charging/operational mode controls the cut-off voltage used during charging and the maintenance temperature of the battery pack.

Abstract: A method and apparatus that allows the end user to optimize the performance of an all-electric or hybrid vehicle and its charging system for a desired mode of operation is provided. The system of the invention includes multiple charging/operational modes from which the user may select. Each charging/operational mode controls the cut-off voltage used during charging and the maintenance temperature of the battery pack.

Abstract: A method and apparatus that allows the end user to optimize the performance of an all-electric or hybrid vehicle and its charging system for a desired mode of operation is provided. The system of the invention includes multiple charging/operational modes from which the user may select. Each charging/operational mode controls the cut-off voltage used during charging and the maintenance temperature of the battery pack.

Abstract: A rotor assembly cooling system (100) and method of using same are provided. A portion of the rotor shaft (103) is hollow, the rotor shaft including an open end (107) and a closed end (105). A coolant feed tube (109) is rigidly attached to the rotor shaft (103) using one or more support members (111), thus causing the shaft and the feed tube to rotate at the same rate. Coolant is pumped through the feed tube until it exits the end of the feed tube and flows against the inside surface of the closed end of the rotor shaft causing the coolant to change direction and flow back through the coolant flow region, this region being defined as the space between the outer surface of the feed tube and the inner surface of the hollow rotor shaft.

Abstract: A method of communicating with an electric vehicle wherein the method includes a step of installing a communication device in the electric vehicle. The method also includes establishing a connection from the vehicle to a network. The methodology also includes controlling and monitoring a battery in the electric vehicle.

Abstract: A method and apparatus for deactivating a bad battery cell from a battery pack for an energy storage system of an electric vehicle is disclosed. The apparatus and methodology includes a clamshell member arranged at an end of the cells and a printed circuit board arranged adjacent to the clamshell member. A collector plate is arranged adjacent to the printed circuit board and a switch is arranged on the printed circuit board. A wire bond is arranged between the switch and one of the cells and a second wire bond is arranged between the switch and the collector plate. The plurality of switches will allow for the identification of the one individual cell having a weak short circuit within the battery pack. Upon identification of the cell with the weak short circuit that cell will have its switch placed in an open position thus electrically isolating the faulty or bad cell from the battery pack.

Abstract: A battery pack thermal management system for use in an electric car. The battery pack thermal management system includes a plurality of thermistors connected to a plurality of cells of a battery pack. A battery monitor board is connected to the thermistors. The system also includes a manifold and a plurality of cooling tubes connected to the manifold. A tube seal plug is arranged over an end of the cooling tube and an end fitting is arranged on an end of the cooling tube. The thermal management system will cool the battery pack to predetermined temperatures to increase the longevity of the battery pack within the electric vehicle.

Abstract: A rotor assembly cooling system (100) and method of using same are provided. A portion of the rotor shaft (103) is hollow, the rotor shaft including an open end (107) and a closed end (105). A coolant feed tube (109) is rigidly attached to the rotor shaft (103) using one or more support members (111), thus causing the shaft and the feed tube to rotate at the same rate. Coolant is pumped through the feed tube until it exits the end of the feed tube and flows against the inside surface of the closed end of the rotor shaft causing the coolant to change direction and flow back through the coolant flow region, this region being defined as the space between the outer surface of the feed tube and the inner surface of the hollow rotor shaft.

Abstract: An MRIS gradient coil structure has coiled tubes for carrying a cooling medium to cool the coil structure. The inlet and outlet (15, 26) of the coiled tubes are insulated electrically from the remainder thereof by a ceramic insulator (20).