Abstract: Methods and systems are provided for managing multi-battery systems, such as those utilized in an electric vehicle. Multi-battery systems comprise batteries providing power in parallel, thereby making each battery available to the vehicle and avoiding the weight of transporting a backup battery. The methods and systems provided allow for a fault in one battery, in a parallel configuration with at least one other battery, to be detected and managed.

Abstract: Embodiments are directed to managing battery pack exchanges for an electric vehicle by maintaining current swap station information for a number of battery pack swap stations, receiving navigation information from the vehicle indicating a travel route of the vehicle, and receiving current vehicle information from the vehicle and related to a battery pack installed in the vehicle. A battery pack swap plan can be determined based on the swap station information, the navigation information, and the vehicle information. The plan can indicate a selected replacement battery pack at each of one or more selected battery pack swap stations. Information defining the battery pack swap plan can be provided to the selected battery pack swap stations and the vehicle. The stations can reserve the selected replacement battery pack and the vehicle can update the travel route based on the battery pack swap plan.

Abstract: A battery connector, including a flexible circuit including a first set of electrical circuitry connecting to a plurality of energy storage cells, where the first set of electrical circuitry terminates at a first connection point at the battery connector; a controller including components to control the energy storage cells connected to a second set of electrical circuitry terminating at a second connection point at the battery connector; where the first connection point and the second connection point are electrically connected.

Abstract: Methods, systems, and devices of an electrical vehicle are provided that recognize a catastrophic power system fault with one or more drive power sources of the vehicle and in response driving to an identified safe ejection location, ejecting the faulty drive power sources, and driving to a safe parked location or outside a predetermined safe range. Upon reaching the safe ejection location, the driver or vehicle can evaluate the location using imaging sensors to determine whether the location is free of objects, animals, or people. If not, the vehicle may autonomously drive or be driven to another safe ejection location. After detecting and prior to ejecting the faulty drive power sources, the vehicle may send warning messages, including information about the power system fault, to at least one device or third party. After ejection, the vehicle may be driven to a safe parked location or outside a predetermined safe range.

Abstract: Methods and systems are described that maintain and service electric vehicle battery packs and assemblies. The methods and systems automatically remove a used battery pack from an electric vehicle, replace the used battery pack with a charged battery pack, and service the removed used battery pack for subsequent vehicle installation. The servicing of the used battery pack includes removing a desiccant cartridge from the used battery pack and renewing a desiccant material associated with the desiccant cartridge. This desiccant material may be renewed by drying the desiccant cartridge using a heater. The used battery pack may be conveyed to a battery charger to charge the used battery pack to a predetermined charge level. The renewed, dry, desiccant cartridge may be attached to any battery pack and installed in an electric vehicle after the battery pack has been charged.

Abstract: Methods and systems are described that maintain and service electric vehicle battery packs and assemblies. The methods and systems automatically remove a used battery pack from an electric vehicle, replace the used battery pack with a charged battery pack, and service the removed used battery pack for subsequent vehicle installation. The servicing of the used battery pack includes removing a desiccant cartridge from the used battery pack and renewing a desiccant material associated with the desiccant cartridge. This desiccant material may be renewed by drying the desiccant cartridge using a heater. The used battery pack may be conveyed to a battery charger to charge the used battery pack to a predetermined charge level. The renewed, dry, desiccant cartridge may be attached to any battery pack and installed in an electric vehicle after the battery pack has been charged.

Abstract: A battery connector, including a flexible circuit including a first set of electrical circuitry connecting to a plurality of energy storage cells, where the first set of electrical circuitry terminates at a first connection point at the battery connector; a controller including components to control the energy storage cells connected to a second set of electrical circuitry terminating at a second connection point at the battery connector; where the first connection point and the second connection point are electrically connected.

Abstract: Methods, systems, and devices of an electrical vehicle are provided that recognize a catastrophic power system fault with one or more drive power sources of the vehicle and in response driving to an identified safe ejection location, ejecting the faulty drive power sources, and driving to a safe parked location or outside a predetermined safe range. Upon reaching the safe ejection location, the driver or vehicle can evaluate the location using imaging sensors to determine whether the location is free of objects, animals, or people. If not, the vehicle may autonomously drive or be driven to another safe ejection location. After detecting and prior to ejecting the faulty drive power sources, the vehicle may send warning messages, including information about the power system fault, to at least one device or third party. After ejection, the vehicle may be driven to a safe parked location or outside a predetermined safe range.

Abstract: Methods and systems are provided for managing multi-battery systems, such as those utilized in an electric vehicle. Multi-battery systems comprise batteries providing power in parallel, thereby making each battery available to the vehicle and avoiding the weight of transporting a backup battery. The methods and systems provided allow for a fault in one battery, in a parallel configuration with at least one other battery, to be detected and managed.

Abstract: Embodiments are directed to managing battery pack exchanges for an electric vehicle by maintaining current swap station information for a number of battery pack swap stations, receiving navigation information from the vehicle indicating a travel route of the vehicle, and receiving current vehicle information from the vehicle and related to a battery pack installed in the vehicle. A battery pack swap plan can be determined based on the swap station information, the navigation information, and the vehicle information. The plan can indicate a selected replacement battery pack at each of one or more selected battery pack swap stations. Information defining the battery pack swap plan can be provided to the selected battery pack swap stations and the vehicle. The stations can reserve the selected replacement battery pack and the vehicle can update the travel route based on the battery pack swap plan.

Abstract: Methods and systems are provided for managing multi-battery systems, such as those utilized in an electric vehicle. Multi-battery systems comprise batteries providing power in parallel, thereby making each battery available to the vehicle and avoiding the weight of transporting a backup battery. The methods and systems provided allow for a fault in one battery, in a parallel configuration with at least one other battery, to be detected and managed.

Abstract: A thermal management system of a battery of an electric vehicle proactively manages the temperature of the battery based on sensor data and sets limits to control cooling and heating of the battery. Using the data gathered from an autonomous drive platform, a highly-efficient control system which uses predictive modelling can be created. A control system predicts the battery final temperature and determines if cooling and/or heating is necessary for the route. If cooling and/or heating is not necessary, the thermal management system may be simply turned off to save energy. This is a dynamic approach which should optimize energy usage under all situations using trip predictive information (from GPS, route-calculation algorithms, and weather information), and thermal model predictive controls to determine battery final temperatures.

Abstract: An energy storage device that includes energy storage cells, each of the energy storage cells having a top side and a bottom side, where sets of the energy storage cells are arranged in a pattern with the top sides of each of the energy storage cells being adjacent to one another; and a coldplate positioned between two of the sets of the energy storage cells, where the energy storage cells are mechanically connected to the coldplate on opposing sides of the coldplate.

Abstract: A laminated busbar assembly includes positive and negative leads supported by an insulative layer. The insulative layer as well as the positive and negative leads are thin and flexible, thus facilitating connection of the positive and negative leads with the terminals of the electric cells of a battery module. The laminated busbar assembly may include voltage measurement wires and/or temperature sensors for measuring voltage and/or temperature, respectively.

Abstract: Systems and methods of detecting leakage and other issues with electrical battery housings are provided. By using an air compressor to alter the air pressure within a battery housing, a processor may detect an abnormal rate of change in the air pressure within the battery housing as compared to a rate of change of an ideal battery housing.

Abstract: An energy storage device having improved safety is provided, and methods of manufacturing the same. The device can be an electrochemical cell that includes: a positive electrode including a positive electrode active material in electrically conductive contact with a positive electrode current collector; a negative electrode including a negative electrode active material in electrically conductive contact with a negative electrode current collector and a negative electrode tab connected to the negative electrode current collector and a negative electrically conductive member; an electrically insulative and ion conductive medium in ionically conductive contact with the positive electrode and the negative electrode; and an outer case containing the positive electrode, negative electrode and electrically insulative and ion conductive medium, where the outer case comprises a scored area connected to a cooling plate.

Abstract: A multiple-zone thermocouple battery module temperature monitoring system is provided configured to determine a plurality of temperatures along a depth of the battery module at different locations. The system may include a number of temperature probes each including a first temperature sensor oriented at a base of a group of cells in the module and a second temperature sensor oriented at an upper portion of the group of cells in the module. Providing upper and lower battery cell temperature sensors in each probe of the system allows a battery management system to detect and record a temperature gradient of the battery cells in the module at a number of different locations. These recordings can determine a gradient and temperature difference between the upper and lower battery cell portions over an operable threshold difference, and command a thermal management system to return the battery module to limits within the operable threshold.

Abstract: Embodiments include a junction box for an electric vehicle. The junction box includes a charging port to receive power from an external power source, and a plurality of switching elements to control electrical connections between the charging port, a first battery, and a second battery. On/off states of the plurality of switching elements control whether the charging port, the first battery and the second battery are connected in a first configuration or a second configuration.

Abstract: A laminated busbar assembly includes positive and negative leads supported by an insulative layer. The insulative layer as well as the positive and negative leads are thin and flexible, thus facilitating connection of the positive and negative leads with the terminals of the electric cells of a battery module. The laminated busbar assembly may include voltage measurement wires and/or temperature sensors for measuring voltage and/or temperature, respectively.

Abstract: An energy storage module having improved design and functionality is provided, and methods of manufacturing the same. The device can be a battery module that includes: energy storage cells, each of the energy storage cells having an upper side and a lower side, where the energy storage cells are arranged in a pattern with each energy storage cell being spaced apart from one another, and wherein the upper sides of each of the energy storage cells are adjacent to one another; a cold plate including a transparent material; and a UV-cured adhesive in contact with the cold plate and each of the energy storage cells.