Abstract: Methods and systems for welding a terminal of a battery cell to corresponding terminal tab or busbar are described using a magnet that causes the terminal and tab/busbar to be placed in physical contact. The terminal of a battery cell is aligned in contact with the tab/busbar by the force of a magnetic field. A welder, e.g., a laser welder, can then generate a laser weld beam to weld the terminal of the battery cell to the tab/busbar. Next, the laser weld beam is narrowed, reducing the first diameter to a smaller second diameter. Without touching the tab/busbar or terminal of the battery (which could affect the welding operation), the magnetic field can cause a force that brings the tab and terminal in contact during welding.

Abstract: Devices and systems are provided that incorporate fusible links within the electrical traces of a battery module voltage sensing circuit. The fusible links can be integrally formed in an electric trace and provide an overcurrent protection feature for the circuit without requiring fuse elements or components that are separate from the electrical trace. Each of these fusible links include a substantially flat controlled cross-sectional area disposed along a length of the material making up the electrical trace. In an overcurrent situation, the connection between a battery management system and a battery cell may be severed by the overcurrent melting the fusible link. The electrical traces may be spaced apart from one another in the circuit such that an overcurrent situation breaking the connection between one cell and the battery management system would not affect adjacent electrical traces not having an overcurrent situation.

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: A tapered busbar for an energy storage device is provided. The tapered busbar is configured to interconnect with a first row of series-connected energy storage cells in a battery module at a first end of the busbar. As the busbar tapers from a first cross-sectional area at the first end to a larger second cross-sectional area at a second opposite end, the busbar is configured to interconnect with sequentially additional electrically-parallel rows of series-connected energy storage cells. The tapered cross-sectional area of the busbar provides a substantially uniform current density at any point along the length of the busbar regardless of the number of rows of energy storage cells connected before or after the point.

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: 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: An energy storage device and structurally enhanced packaging for energy storage cells is provided. The energy storage device includes a number of energy storage cells spaced apart from one another and contained in a lightweight carrier. The energy storage cells and carrier are mechanically coupled together with a structural adhesive forming a unified structure and framework where each connection point acts as a node in a force distribution structure. The structural adhesive can be injected into the volume between the energy storage cells while in a fluid, or semi-fluid, state. While in this state, a retaining form or gasket inside the carrier can prevent the structural adhesive from leaking out of the energy storage device. When in a cured, or hardened, non-fluid state the structural adhesive may adhere to the various components of the energy storage device to mechanically join the component together into a structurally safe package.

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: Devices, methods, and systems for interconnecting all of the battery cells in a battery module from a single side of the battery cell and module are provided. The cell busbar system comprises a number of thin formed strips arranged to interconnect individual battery cells in a row together in series and each row in parallel along a length of the battery module. In particular, the cell busbar system may include two high voltage, or edge, strips and a number of cell-to-cell, or internal, strips electrically interconnected to the edge strips. All of the battery cells in the battery module may be oriented such that all of the positive terminals are facing the same direction. The interconnections between series-connected rows of cells, and parallel rows of series-connected rows, may all be made in substantially the same plane on a single side of the battery module.

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: Battery charging systems and the operations thereof are provided. The battery charging systems provide fast charging. The battery charging systems include a charging unit, a battery, a battery management system, and a number of sensors and battery monitors. The battery includes one or more cells. The battery charging systems include a fast-charge profile including a number of stages.

Abstract: An energy storage device including a staggered energy storage cell internal array with two-dimensional inline terminal edges is provided. The energy storage cells in a battery module may be staggered in an internal array, such that a first row of cells in a line are spaced apart, or offset, in a first direction from an immediately adjacent second row of cells in a line, and wherein a first cell in the second row of cells is offset from a first cell in the first row of cells in a second direction orthogonal to the first direction. In some cases, at least two adjacent rows in the battery module may include energy storage cells that are offset from one another but aligned in one direction, such as, the second direction. A mechanical frame may define the arrangement of the energy storage cells relative to one another.

Abstract: A system and method for an energy storage device having improved thermal management is provided. The system includes a number of energy storage cells spaced apart from one another and contained in a housing that can be pressure sealed. The system can include a pipe containing fluid circulating within the pipe and a liquid within the housing, where an amount of the liquid is less than half of a volume within the housing. Thermal energy is transferred between an area within the housing and at least a portion of a wall of the pipe.

Abstract: Methods and systems for creating a battery module. A battery cell can include a cooling device that cools a busbar and a power electronics package. To allow the cooling device to be attached to the busbar and allow the cooling device to cool both the power electronics and the busbar, the cooling device is mounted on the busbar with the busbar held between two portions of the cooling device and with the power electronics mounted on an opposite side of the cooling device from the busbar. The fluid or phase change material may then circulate through a cavity in the cooling device to cool both the power electronics and the busbar.

Abstract: Systems of an electrical vehicle and the operations thereof are provided. Batteries, such as standardized batteries, may allow supplemental batteries to be deployed for use by an electric vehicle. Accordingly, a battery and management system are provided to allow a supplemental battery to provide power to a main battery. Additionally, a battery charging system may sequence the charging of batteries based on whether or not the duration of the charge is known and/or sufficient to charge at least the main battery.

Abstract: Embodiment include a power source module comprising one or more power cells. Each power cell can comprise a pressure vent on a side of the power cell. The pressure vent can be adapted to relieve an internal pressure of the cell when the internal pressure exceeds a threshold. A cooling plate can be disposed adjacent and substantially parallel to a side of the one or more power cells having the pressure vent. One or more spacers can be disposed between each of the one or more power cells and the cooling plate and substantially surrounding the pressure vent of one of the one or more power cells. A thermally conductive potting material can be disposed between the one or more power cells and the cooling plate. Each spacer prevents the potting material from intruding into an area around the vent of one of the one or more power cells.

Abstract: Systems of an electrical vehicle and the operations thereof are provided. In particular, a vehicle is described with the ability to gather State of Charge (SOC) information as well as State of Health (SOH) information for one or more batteries in a vehicle and then display both SOC and SOH information to a driver of the vehicle as well as other interested parties. The displayed SOH information may be accompanied by suggestions to modify driving and/or charging behaviors that will improve or contribute to a slower degradation in the SOH of the batteries.

Abstract: An energy storage device and structure for energy storage cells is provided that includes a plurality of energy storage cells, each of the energy storage cells having side surface areas. The plurality of energy storage cells are arranged in a pattern with each energy storage cell being spaced a specified distance apart from one another. An expandable material is adhered, by an adhesive backing, to at least a portion of the side surface areas of one or more of the energy storage cells, and the expandable material expands within and at least part of the specified distance.

Abstract: Systems of an electrical vehicle and the operations thereof are provided. More particularly, a vehicle including a first charging port at a first location on the vehicle and a second charging port at a second location on the vehicle is provided. The first charging port of the vehicle may be different from the second charging port of the vehicle. That is, a standard associated with a receptacle of the first charging port may be different from a standard associated with a receptacle of the second charging port.

Abstract: Methods and systems for creating a battery module. A battery cell can include a vent in the bottom of the battery. To allow the battery to be attached to a cooling plate and allow the vent to function properly, an opening is formed in the cooling plate under the battery. The opening can vent gasses from the vent in the battery to atmosphere through a chamber in the cooling plate or a conduit in the cooling plate.