Abstract: A vehicle includes an electric motor, one or more low-voltage components, a high-voltage battery pack, and a direct current to direct current (DC-to-DC) converter. The high-voltage battery pack includes one or more high-voltage battery strings configured to provide a high-voltage output on a high-voltage bus for powering the electric motor. The DC-to-DC converter is connected to the one or more high-voltage battery strings, and is configured to generate a low-voltage output on a low-voltage bus for powering the one or more low-voltage components.

Abstract: A vehicle includes an electric motor, one or more low-voltage components, a high-voltage battery pack, and a direct current to direct current (DC-to-DC) converter. The high-voltage battery pack includes one or more high-voltage battery strings configured to provide a high-voltage output on a high-voltage bus for powering the electric motor. The DC-to-DC converter is connected to the one or more high-voltage battery strings, and is configured to generate a low-voltage output on a low-voltage bus for powering the one or more low-voltage components.

Abstract: A traction battery assembly includes, among other things, a battery cell array having a plurality of individual battery cells. The battery cell array usable with a first busbar module having a first arrangement of busbars. The battery cell array is also usable with a second busbar module having a second arrangement of busbars. When the battery cell array is used with the first busbar module, the battery cell array is partitioned into a first number of groups of battery cells in parallel with each other. When the battery cell array is used with the second busbar module, the battery cell array is partitioned into a different, second number of groups of battery cells in parallel with each other.

Abstract: This disclosure relates to an access cover detection circuit for an electrified vehicle component and a corresponding method. An exemplary component of an electrified vehicle includes an access cover configured to selectively open and close relative to the component, and a circuit configured to indicate whether the access cover is open. The circuit includes a light sensitive electronic component.

Abstract: An apparatus and method, according to an exemplary aspect of the present disclosure includes, among other things, a battery pack having a coolant inlet and a coolant outlet, a coolant source to cool the battery pack, and a proportional valve in communication with the coolant inlet and the coolant outlet, and in communication with the coolant source. A battery control module controls the proportional valve such that a direction of flow is switchable at the coolant inlet and the coolant outlet based on temperatures at the coolant inlet and the coolant outlet to provide bi-directional cooling flow through the battery pack. The battery control module directly connects the coolant outlet to the coolant inlet via the proportional valve to bypass the coolant source in response to a predetermined condition.

Abstract: A traction battery assembly includes, among other things, a battery cell array having a plurality of individual battery cells. The battery cell array usable with a first busbar module having a first arrangement of busbars. The battery cell array is also usable with a second busbar module having a second arrangement of busbars. When the battery cell array is used with the first busbar module, the battery cell array is partitioned into a first number of groups of battery cells in parallel with each other. When the battery cell array is used with the second busbar module, the battery cell array is partitioned into a different, second number of groups of battery cells in parallel with each other.

Abstract: A busbar assembly includes a mesh busbar configured to electrically couple a first component to a second component. An electrical coupling method including securing a mesh busbar to a first component and a second component to electrical couple the first component to the second component.

Abstract: An apparatus and method, according to an exemplary aspect of the present disclosure includes, among other things, a battery pack having a coolant inlet and a coolant outlet, a coolant source to cool the battery pack, and a proportional valve in communication with the coolant inlet and the coolant outlet, and in communication with the coolant source. A battery control module controls the proportional valve such that a direction of flow is switchable at the coolant inlet and the coolant outlet based on temperatures at the coolant inlet and the coolant outlet to provide bi-directional cooling flow through the battery pack. The battery control module directly connects the coolant outlet to the coolant inlet via the proportional valve to bypass the coolant source in response to a predetermined condition.

Abstract: A method and apparatus includes, among other things, a plurality of battery cells laid next to each other such that cell tabs from one battery cell overlap cell tabs from an adjacent battery cell to form a set of overlapped cell tabs. Each set of overlapped cell tabs are directly joined to each other at a connection interface. A voltage sense circuitry is directly attached to the cell tabs.

Abstract: This disclosure relates to an access cover detection circuit for an electrified vehicle component and a corresponding method. An exemplary component of an electrified vehicle includes an access cover configured to selectively open and close relative to the component, and a circuit configured to indicate whether the access cover is open. The circuit includes a light sensitive electronic component.

Abstract: An exemplary busbar forming method includes, among other things, creasing a sheet of material to form a plurality of creases that partition the sheet into a plurality of segments. The method further includes identifying a desired size for a terminal receiving recess in a busbar. In response to the desired size, the method folds at least some of the segments relative to each other about at least some of the creases according to a first process, or a different, second process. An exemplary battery assembly includes, among other things, a busbar formed from a sheet of material. The busbar has a terminal receiving recess. Creases are formed within the sheet that partition at least a portion of the sheet into a plurality of segments. Some of the segments are folded relative to each other about at least some of the creases to provide the terminal receiving recess in the busbar.

Abstract: A hybrid electric vehicle having battery packs coupled to the vehicle in parallel, which each include series-connected cells, a single contactor, a battery pack controller that detects cell voltages, and at least one controller coupled to a bus contactor and the packs. Responsive to a vehicle key on signal, the at least one controller closes the single battery pack contactor for at least one of the battery packs that includes voltage balanced cells. The bus contactor is then closed to deliver electrical power to the vehicle, and may include a precharge contactor that is closed in advance of and until the bus contactor open circuit voltage is reduced to a contactor voltage difference. The battery pack controllers are further configured to detect voltage, current, and temperature of each cell, to open the single contactor, and to adjust the state of charge of unbalanced cells until balanced relative with the others.

Abstract: A busbar assembly includes a mesh busbar configured to electrically couple a first component to a second component. An electrical coupling method including securing a mesh busbar to a first component and a second component to electrical couple the first component to the second component.

Abstract: A vehicle includes an electric machine, a battery, an inverter, and a flexible circuit. The electric machine is configured to propel the vehicle. The inverter is configured to convert direct current from the battery into alternating current. The flexible circuit has a sensor embedded therein that is configured to measure a first phase of the alternating current. The sensor is secured to an output terminal of the inverter that is connected to a first winding phase of the electric machine.

Abstract: A vehicle charging includes a housing, a sensor system configured to detect if a vehicle is parked near the housing, and a notification system configured to communicate an alert if the vehicle is parked near the housing and charging has not been initiated within a threshold amount of time. The alert indicates improper usage of the vehicle charging station to an operator of the vehicle.

Abstract: An exemplary busbar forming method includes, among other things, creasing a sheet of material to form a plurality of creases that partition the sheet into a plurality of segments. The method further includes identifying a desired size for a terminal receiving recess in a busbar. In response to the desired size, the method folds at least some of the segments relative to each other about at least some of the creases according to a first process, or a different, second process. An exemplary battery assembly includes, among other things, a busbar formed from a sheet of material. The busbar has a terminal receiving recess. Creases are formed within the sheet that partition at least a portion of the sheet into a plurality of segments. Some of the segments are folded relative to each other about at least some of the creases to provide the terminal receiving recess in the busbar.

Abstract: A hybrid electric vehicle having battery packs coupled to the vehicle in parallel, which each include series-connected cells, a single contactor, a battery pack controller that detects cell voltages, and at least one controller coupled to a bus contactor and the packs. Responsive to a vehicle key on signal, the at least one controller closes the single battery pack contactor for at least one of the battery packs that includes voltage balanced cells. The bus contactor is then closed to deliver electrical power to the vehicle, and may include a precharge contactor that is closed in advance of and until the bus contactor open circuit voltage is reduced to a contactor voltage difference. The battery pack controllers are further configured to detect voltage, current, and temperature of each cell, to open the single contactor, and to adjust the state of charge of unbalanced cells until balanced relative with the others.

Abstract: A vehicle charging includes a housing, a sensor system configured to detect if a vehicle is parked near the housing, and a notification system configured to communicate an alert if the vehicle is parked near the housing and charging has not been initiated within a threshold amount of time. The alert indicates improper usage of the vehicle charging station to an operator of the vehicle.

Abstract: A power system is disclosed. The system may include an electrical contactor including a pair of plates arranged to scissor between open and closed positions. The plates may have magnets embedded therein such that in the closed position, a subset of the magnets having opposite polarity are aligned to encourage touching of electrical contacts of the plates, and in the open position, a subset of the magnets having same polarity are aligned to encourage separation of the electrical contacts.

Abstract: A power system is disclosed. The system may include an electrical contactor including a pair of plates arranged to scissor between open and closed positions. The plates may have magnets embedded therein such that in the closed position, a subset of the magnets having opposite polarity are aligned to encourage touching of electrical contacts of the plates, and in the open position, a subset of the magnets having same polarity are aligned to encourage separation of the electrical contacts.