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. 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 of an electrical vehicle are provided that recognize a power system fault with the vehicle and in response autonomously drive the vehicle to an identified safe location to self-destruct. Upon reaching the location, the 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 to another safe location. Prior to destruction, the vehicle sends messages, including information about the power system fault, to at least one device or third party. The messages include location information for the vehicle or information about the power system fault.

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.

Abstract: Systems of an electrical vehicle and the operations thereof are provided. As vehicles become self-driven, safety should be improved. In the rare occurrence that a vehicle is performing an incorrect function or in an incorrect manner, the passengers need to be able to shut down the car and evacuate the vehicle in a safe manner. Highlighted by this is ride sharing vehicle that picks random passengers up. Inside the vehicle would be an override switch. When initiated, the override switch would send a lower level command to the vehicle control unit overriding any upper level signals, alert any near cars of the issue and immediately pull over and bring to a complete stop (unlocking all doors as well) the vehicle. This could optionally be coupled with one or more mechanical/electrical shut down/disconnect mechanisms.

Abstract: Methods, devices, and systems of a sensor surface object detection system are provided. Output from sensors of a vehicle may be used to describe an environment around the vehicle. In the event that a sensor is obstructed by dirt, debris, or detritus the sensor may not sufficiently describe the environment for autonomous control operations. The sensor surface object detection system may receive output from the sensors of the vehicle to determine whether any of the sensors are obstructed. The determination may be made by comparing the output of one sensor to another, determining whether the output of a sensor is within a predetermined threshold, or comparing characteristics of multiple sensor outputs to one another. When a sensor is determined to be obstructed, the system may send a command to a cleaning system to automatically remove the obstruction.

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 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: A battery module cell cover is provided including a number of features configured to orient, capture, and isolate battery cell interconnections relative to battery cell locations in an array of battery cells. Isolation features may block a negative terminal battery cell interconnect from moving out of an orientation receptacle aligned with a negative terminal of a battery cell and into contact with a positive terminal of the battery cell, or vice versa. The battery module cell cover can include a number of structural connection features protruding from a planar surface into a battery cell containment cavity, between battery cell locations, that provide a number of surfaces for curing to structural adhesive of the battery module. These structural connection features, in conjunction with the structural adhesive, can assist in forming a unified strengthened structure of the battery module.

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: Methods and systems for ejecting a charger handle from an electrical vehicle are provided. In the event that a power system fault or incident is detected, the charger handle of an external vehicle charging system may be automatically and physically separated from the vehicle. The fault or incident can be detected by the vehicle or the external vehicle charging system. The charger handle is ejected using a charging connection separation mechanism. This mechanism can be part of the charging system or part of the vehicle.

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 of an electrical vehicle and the operations thereof are provided that control an operating temperature of an on board battery pack using an external thermal management system.

Abstract: Systems of an electrical vehicle and the operations thereof are provided. In particular, a motor controller is described. The motor controller is described to have the ability to emit an electromagnetic signal via a motor of the electrical vehicle. The motor controller may be designed to control a speed of the motor's rotation so as to control a frequency of the emitted electromagnetic signal.

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: Methods and systems of an electrical vehicle are provided that detect a power system fault, determine a presence of at least one occupant in the vehicle, and determine an escape route from the vehicle for the at least one occupant. In determining the escape route, the vehicle determines an environment around the vehicle, a location of the power system fault in the vehicle, and a location of the at least one occupant in the vehicle. Based on this information, the vehicle provides an escape route from the vehicle to direct the at least one occupant to a safe area outside of the vehicle. The escape route is provided to the user via at least one display device associated with the vehicle.

Abstract: Systems of an autonomous vehicle and the operations thereof are provided. During travel of an autonomous vehicle, the autonomous vehicle, the autonomous vehicle can determine a charge is needed. Within the planned path of travel, the autonomous vehicle can determine when the autonomous vehicle may arrive at a charging station, what destinations are planned after reaching the charging station, the current temperature of the battery (and the temperature of the surroundings), the weather conditions at the charging station, etc. Based on these determinations and/or calculations, the autonomous vehicle can precondition the battery before the autonomous vehicle arrives at the charging station, for example, the autonomous vehicle starts cooling the battery at a quicker than normal rate so that the autonomous vehicle arrives at the charging station with the battery at the coldest possible temperature.

Abstract: A modular battery assembly includes at least a first battery pack and a second battery pack. Each battery pack includes a container at least partially enclosing a first plurality of electrical storage devices, an attachment mechanism configured to removably attach the first container to a chassis of a vehicle, a mechanical connector, and an electrical connector configured to connect the plurality of electrical storage devices to a control section of the vehicle. The battery pack containers are configured to be removably attached to each other by connection of the mechanical connectors.

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: Methods and systems provide for the manufacture of a cylindrical battery cell case that is changed from steel (or nickel-plated steel) to aluminum. With this change, spot welding the copper tab from the anode to the aluminum case will result in the copper and aluminum corroding over time—leading to early battery failure. To manufacture the battery with the aluminum case, one or more manufacturing changes are made including one or more of: 1. changing the polarity of the battery to spot weld the copper tab to a steel top of the battery; 2. coating the copper tab with a second material to prevent corrosion; and/or, 3. use a different welding method (e.g., a friction stir weld) to fuse the copper tab to the aluminum case.