Abstract: A charging method using a multiphase line voltage for charging an energy storage system (ESS) using a polyphase motor drive circuit communicated to a polyphase motor, the polyphase motor drive circuit including a plurality M of driver stages, one driver stage for each phase of the polyphase motor with each driver stage coupled across the energy storage system, the method including the steps of: (a) determining a charge mode responsive to a comparison of the multiphase line voltage to a voltage of the energy storage system, the determined charge mode including a boost mode when the voltage of the energy storage system has a first predetermined relationship to the multiphase line voltage and the determined charge mode including a boost-buck mode when the voltage of the energy storage system has a second predetermined relationship to the multiphase line voltage; (b) converting, when the charge mode includes the boost mode, the multiphase line voltage to a first charging voltage using a first set of N number of t

Abstract: A charging method using an alternating current (AC) line voltage for conductive charging of an energy storage system (ESS) coupled to a polyphase motor drive circuit communicated to a polyphase motor, the polyphase motor drive circuit including a plurality M of driver stages, one driver stage for each phase of the polyphase motor with each driver stage coupled across the energy storage system, the method including the steps of: (a) coupling a first connector providing the line voltage to a second connector coupled to the plurality of driver stages; (b) interrupting selectably the line voltage from communication with the plurality of driver stages; (c) measuring both an ESS common mode voltage of the energy storage system with respect to a voltage reference and a line common mode voltage of the line voltage with respect to the voltage reference while the line voltage communication to the plurality of driver stages is interrupted; (d) operating a particular one of the driver stages to power a common mode voltag

Abstract: A test apparatus and corresponding method for simulating an internal cell short and initiating thermal runaway in a battery cell is disclosed whereby the cell is internally heated through rapid charge and discharge cycles at high currents. The magnitude of the selected current may be modulated to simulate a cell short with the desired power profile without unrealistically heating neighboring cells or interfering with the thermal environment of the cell within the module.

Abstract: A system and method including a runtime thermal model that estimates individual component temperatures, permitting the system to only limit power when necessary or desirable. A power-limiting system for a vector-controlled AC induction motor includes a torque command system for generating a torque command; a thermal protection system determining a runtime estimate for a temperature of a component of a rotational electro-magnetic component of the vector-controlled AC induction motor; and a controller configured to generate a motor control signal for the vector-controlled AC induction motor responsive to the torque command, wherein the thermal protection system determines the runtime estimate responsive to a multi-node thermal model of the vector-controlled AC induction motor, and wherein the controller limits a power of the vector-controlled AC induction motor to maintain a component temperature below its critical temperature.

Abstract: A method and apparatus for controlling a particular vehicle function, for example the adjustment of a vehicle seat, using a graphical user interface (GUI) is provided. The GUI is activating by toggling a control, switch intuitively linked to the particular vehicle function. The control switch is separate from, and not proximate to, the GUI. When the GUI is activated by toggling the control switch, a control screen specific to the particular vehicle function is displayed on the GUI.

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: Controlled electrokinetic transport of constituents of liquid media can be achieved by connecting at least two volumes containing liquid media with at least one dielectric medium with opposing dielectric surfaces in direct contact with said liquid media, and establishing at least one conduit across said dielectric medium, with a conduit inner surface surrounding a conduit volume and at least a first opening and a second opening opposite to the first opening. The conduit is arranged to connect two volumes containing liquid media and includes a set of at least three electrodes positioned in proximity of the inner conduit surface. A power supply is arranged to deliver energy to the electrodes such that time-varying potentials inside the conduit volume are established, where the superposition of said potentials represents at least one controllable traveling potential well that can travel between the opposing conduit openings.

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 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 for configuring and personalizing a vehicle user interface is provided, the user interface utilizing a touch screen display mounted within the vehicle. User configurable aspects of the user interface include the number of zones within the touch screen display, the size of each zone, the subsystem interface assigned to each zone, the style and information contained within each subsystem interface, display brightness levels for the overall display or per zone, and the assignment and location of persistent soft buttons.

Abstract: An apparatus and method for these embodiments of the present invention, useful in manufacturing for example, includes a plurality of battery modules serially intercoupled together, each module including a housing with an anode connector and a cathode connector, each housing including a memory for storing a module identifier and wherein an anode connector of a first module is coupled to a cathode connector of a second module; and a processing system, coupled to each the module, for determining a plurality of positional attributes of each the module, one positional attribute associated with each the module of the plurality of modules, the processing system writing an ID into the memory of each particular module responsive to the associated positional attribute for the particular module.

Abstract: A dual mode, thermal management system for use in a vehicle is provided. At a minimum, the system includes a first coolant loop in thermal communication with a battery system, a second coolant loop in thermal communication with at least one drive train component (e.g., electric motor, power electronics, inverter), and a dual mode valve system that provides means for selecting between a first mode where the two coolant loops operate in parallel, and a second mode where the two coolant loops operate in series.

Abstract: An apparatus and method for identifying a presence of a short circuit in a battery pack. A fault-detection apparatus for a charging system that rapidly charges a collection of interconnected lithium ion battery cells, the safety system includes a data-acquisition system for receiving a set of data parameters from the collection while the charging system is actively charging the collection; a monitoring system evaluating the set of data parameters to identify a set of anomalous conditions; and a controller comparing the set of anomalous conditions against a set of predetermined profiles indicative of an internal short in one or more cells of the collection, the controller establishing an internal-short state for the collection when the comparing has a predetermined relationship to the set of predetermined profiles.

Abstract: A method of manufacturing a three-phase, four pole motor is provided utilizing a dual-layer winding insertion technique. The first and second winding layers are each comprised of the coil groups for six individual poles, two per phase. Within each layer, the two poles per phase are members of a pole pair. In one configuration, each winding layer is comprised of six concentric coil groups in which there is no coil overlap; alternately, each coil group may be comprised of five coils with either the first or second or both outermost coils of each group being double-turn coils; alternately, each coil group may be comprised of five coils with no coil doubling, although there are overlapping coils from different coil groups; alternately, each coil group may be comprised of five coils with no coil doubling and no overlap between different coil groups, although the coils within each coil group are completely lap wound.

Abstract: One embodiment of the present subject matter includes a battery mounted to a vehicle, with a charge state circuit located in the electric vehicle and coupled to the battery, the charge state circuit configured to provide a charge state signal indicative of the charge state of the battery. The embodiment includes a charging coupler port located proximate to a user accessible exterior of the electrical vehicle and coupled to the battery, the charging coupler port to conduct charging energy to the battery and to provide a charger connection signal indicative of a connection to an external power source. The embodiment also includes a lighting circuit coupled to the charging coupler port and the charge state circuit to control the brightness and color of an illuminated indicator responsive to the charge state signal and the charger connection signal.

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 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: Methods and systems for decreasing costs (expense, mass, and/or cure time) associated with use of adhesives when assembling modularized components, particularly for assemblies having many elements such as for example battery modules used in electric vehicles. The methods and systems enable use of high-wettability adhesives (defined generally in this application as low viscosity and/or low surface tension adhesives) for assembling such modularized components.

Abstract: A method and apparatus for optimizing the level of battery charging required by an electric vehicle is provided. The system includes an interface for the user to input various travel parameters, such as a travel itinerary, which is then used by the battery charging system during charge optimization. In addition to a travel itinerary, the system may be configured to take into account departure times, road conditions, traffic conditions and weather conditions in determining miles to be traveled as well as the electrical energy per mile conversion factors to be used during optimization.

Abstract: A method of charging a rechargeable battery pack installed in an electric vehicle is provided in which the charging system includes a switching circuit that is operable in at least a first mode and a second mode. In the first mode the switching circuit couples the power supply and an external power source to both a heater and the charging circuit, the heater providing a voltage divider circuit within the charging circuit. In the second mode the switching circuit couples the power supply and the external power source only to the charging circuit, bypassing the heater.

Abstract: An apparatus comprising a rechargeable battery pack installed in an electric vehicle, a power supply coupled to the rechargeable battery pack, the power supply operable to provide a charge voltage to perform charging operations on the rechargeable battery pack, a heater to heat a fluid to be circulated through the rechargeable battery pack, the fluid thermally coupled to a plurality of battery cells within the rechargeable battery pack, a switching circuit, the switching circuit coupled to the heater and to the power supply, the switching circuit operable in a first mode to couple the source of electrical power to the heater without coupling the source of electrical power to the rechargeable battery pack, the switching circuit operable in a second mode to couple a source of electrical power external to the electric vehicle to the power supply to form a recharging circuit in order to perform charging operations on the rechargeable battery pack.

Abstract: A center pin for a battery cell that is designed to improve the thermal behavior of a cell during a thermal runaway event is provided in which the center pin is comprised, at least in part, of an intumescent material. The intumescent material may be used to fill a void within the center pin, or to cover an outer surface of the center pin. When the intumescent material covers the center pin, a secondary non-intumescent material may surround the intumescent material, for example in the form of a sleeve, thereby minimizing or preventing chemical reactions from occurring between the intumescent material and the materials comprising the electrode assembly.

Abstract: Systems and methods for diagnosing battery voltage misreporting is described. According to various embodiments, battery voltage may be monitored with respect to a state of charge and/or time. Based on this monitored information, battery charge state data may be generated by computing time derivatives of the monitored battery voltage across a voltage range. This battery charge state data may be compared with an expected set of charge state data if substantial differences exist, an error may be generated. Other embodiments are described and claimed.

Abstract: A voltage converter for charging an energy storage module from an alternating current line voltage, includes a first charging stage, coupled to the energy storage module, converting the line voltage to a first rectified direct current module charging voltage communicated to the energy storage module, the first rectified direct current module charging voltage greater than the line voltage, the first charging stage including an inductance for communicating a first charging current to the energy storage module; a second charging stage, switchably coupled serially with the first charging stage, down-converting the alternating current line voltage to a second rectified direct current module voltage, the second rectified direct current module voltage less than the first rectified direct current module charging voltage, wherein the second charging stage produces a second charging current not greater than the first charging current; and a controller for selectably switching the second charging stage serially with the

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 consist of concentric and non-overlapping coils.

Abstract: Methods and systems for decreasing costs (expense, mass, and/or cure time) associated with use of adhesives when assembling modularized components, particularly for assemblies having many elements such as for example battery modules used in electric vehicles. The methods and systems enable use of high-wettability adhesives (defined generally in this application as low viscosity and/or low surface tension adhesives) for assembling such modularized components.

Abstract: A cooling manifold assembly for use in a battery pack thermal management system is provided. The cooling manifold assembly includes a coolant tube that is interposed between at least a first row of cells and a second row of cells, where the first and second rows of cells are adjacent and preferably offset from one another. A thermal interface layer is attached to the cooling tube, the thermal interface layer including a plurality of pliable fingers that extend away from the cooling tube and are interposed between the cooling tube and the first row of cells, and interposed between the cooling tube and the second row of cells, where the pliable fingers are deflected by, and in thermal contact with, the cells of the first and second rows of cells.

Abstract: A triple-winding layer arrangement for a three-phase, four pole motor is provided as well as a method of manufacturing the same.

Abstract: A cooling manifold assembly for use in a battery pack thermal management system is provided. The cooling manifold assembly includes a coolant tube that is interposed between at least a first row of cells and a second row of cells, where the first and second rows of cells are adjacent and preferably offset from one another. A thermal interface layer is overmolded onto the cooling tube, the thermal interface layer including a plurality of pliable fingers that extend away from the cooling tube and are interposed between the cooling tube and the first row of cells, and interposed between the cooling tube and the second row of cells, where the pliable fingers are deflected by, and in thermal contact with, the cells of the first and second rows of cells.

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 method of manufacturing a triple-winding layer arrangement for a three-phase, four pole motor is provided.

Abstract: A triple-winding layer arrangement for a three-phase, four pole motor is provided as well as a method of manufacturing the same.

Abstract: A high efficiency, high torque density, high speed induction motor is provided, the motor utilizing (i) stator teeth with parallel side surfaces; (ii) rotor teeth with parallel side surfaces; (iii) wide open stator slots; (iv) closed rotor slots with thick tooth bridges; and (v) deep stator and rotor slots.

Abstract: A dual-winding layer arrangement for a three-phase, four pole motor is provided.

Abstract: A dual-winding layer arrangement for a three-phase, four pole motor is provided as well as a method of manufacturing the same.

Abstract: A thermal management system is provided that minimizes the effects of thermal runaway within a battery pack. The system is comprised of a multi-sided, substantially airtight battery pack enclosure configured to hold a plurality of batteries, where at least one side of the battery pack enclosure includes at least one cavity. An inner wall of the enclosure includes a plurality of perforations configured to pass gas from within the enclosure to the cavity within the at least one side member. The system is further comprised of at least one gas exhaust port integrated into an outer wall of the enclosure and configured to pass gas from within the cavity of the enclosure side member to the ambient environment when one or more batteries contained within the battery pack undergo thermal runaway.

Abstract: A battery mounting structure, preferably for use within a battery pack housing, is provided that prevents condensation-induced corrosion from occurring between the terminals of a battery.

Abstract: A battery cell charging system, including a charger and a controller, for rapidly charging a lithium ion battery cell, the battery cell charging system having a circuit for charging the battery cell using an adjustable voltage charging-profile to apply a charging voltage and a charging current to the battery cell wherein the adjustable voltage charging-profile includes: a first charging stage with a constant first stage charging current and an increasing battery cell voltage with the first stage charging current provided until the first stage charging voltage is about equal to a first stage complete voltage less than a maximum battery cell voltage; an intermediate ramped charging stage, the intermediate ramped charging stage including both an increasing ramped voltage and a decreasing ramped iBat current for the battery cell for the voltage charging range of the first stage complete voltage to about the maximum battery cell voltage; and a final charging stage with a constant final stage charging voltage about

Abstract: A system and method for improving cycle lifetimes for a lithium-ion battery pack, particularly for adapting to a dynamic use profile for a user.

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 system and method interconnects battery packs using a flexible bus bar to prevent vibration from breaking or damaging the connections therebetween.

Abstract: A battery is provided that includes a cell case, an electrode assembly and a center pin within the electrode assembly, where the electrode assembly is wrapped around the center pin, and where the center pin is comprised of a material that is rigid within the normal operating temperature range of the battery and deforms, and/or melts, when the battery temperature exceeds the normal operating temperature range of the battery.

Abstract: A battery module for use in an electric vehicle is disclosed. The battery module includes a plurality of cells arranged in a predetermined pattern within the module. The battery module also includes an optical pyrometer arranged inside the module. The optical pyrometer is installed within the module after being tuned to detect a predetermined frequency or band of frequencies. The pyrometer will be used to detect an increase in short wave radiation density from one of the battery cells within the module wherein that battery cell has a temperature above a predetermined threshold. The optical pyrometer will be used to communicate an electric signal to a control system of the electric vehicle wherein that control system will implement a predetermined mitigation process to contain the thermal event of that one cell within the battery module.

Abstract: A power source comprised of a metal-air battery pack and a non-metal-air battery pack is provided, wherein thermal energy from the metal-air battery pack is used to heat the non-metal-air battery pack. In one aspect, a thermal energy transfer system is provided that controls the flow of thermal energy from the metal-air battery pack to the non-metal-air battery pack. In another aspect, the flow of thermal energy from the metal-air battery pack to the non-metal-air battery pack is controlled and used to heat the non-metal-air battery pack prior to charging the non-metal-air battery pack.

Abstract: A system and method disperses a sudden increase in heat generated by one battery cell to a large area including multiple battery cells, thereby preventing the sudden increase from being absorbed primarily by a small number of other battery cells, such as a single battery cell, that could otherwise cause the other battery cells to fail or release their own heat.

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 tunable frangible battery pack system for use in an electric vehicle is disclosed. The tunable frangible battery pack system includes a two piece clamshell housing. The system also includes a plurality of battery cells arranged within the housing and a collector plate secured to each piece of the housing. The system also includes a wire conductor arranged between each of the battery cells and collector plates to create a frangible disconnect system when the battery pack system and electric vehicle are exposed to a predetermined mechanical or thermal force or event.

Abstract: A method for configuring and personalizing a vehicle user interface is provided, the user interface utilizing a touch screen display mounted within the vehicle. User configurable aspects of the user interface include the number of zones within the touch screen display, the size of each zone, the subsystem interface assigned to each zone, the style and information contained within each subsystem interface, display brightness levels for the overall display or per zone, and the assignment and location of persistent soft buttons.

Abstract: A method for using a vehicle user interface is provided, the user interface utilizing a touch screen display mounted within the vehicle. A proximity detection system provides a means for switching the touch screen display from the sleep mode to the normal use mode without the user having to touch the screen, thus expediting user interaction with the touch screen. The proximity detection system may be configured to distinguish the user's presence per touch screen zone, thereby allowing the system controller to switch only a zone of the touch screen from the sleep mode to the normal use mode.

Abstract: A system and a method are provided for configuring the touch-sensitive area and/or the tap duration associated with a plurality of touch-sensitive soft buttons of a vehicle user interface in response to varying vehicle conditions. In particular, as a monitored vehicle condition deteriorates, the system controller coupled to the vehicle user interface expands the touch-sensitive region and/or increases the tap duration of the touch-sensitive soft buttons, thereby improving the user's ability to successfully interact with the interface. Vehicle conditions that may be monitored and used to configure the touch-sensitive area and/or tap duration include passenger cabin vibration levels, vehicle speed, turn radius, lateral force levels, precipitation levels and external ambient temperature.