Abstract: Provided are methods and systems for battery pack thermal management, such as heating and cooling of individual batteries arranged into battery packs. The methods and systems use thermal control modules, specifically configured to thermally couple to the side wall and the bottom end of each battery in a battery pack. In some examples, a thermal control module comprises a thermal plate and one or two battery engagement components, connected and thermally coupled to the thermal plate. Each battery engagement component comprises a plurality of battery receiving openings. When the batteries are installed into these openings, the side wall and the bottom end of each battery are thermally coupled to the thermal control module. Thermal fluid is circulated through at least the thermal plate to provide cooling or heating to the batteries without any direct contact between the thermal fluid and the batteries.

Abstract: A battery enclosure for use in an electric vehicle where the structural support members of the battery enclosure are multi-functional and act to provide support for internally positioned batteries as well as provide additional strength to the framework of the electric vehicle. Furthermore, the structural elements can provide impact resistance to prevent unwanted intrusion into the battery enclosure.

Abstract: A battery enclosure for use in an electric vehicle where the structural support members of the battery enclosure are multi-functional and act to provide support for internally positioned batteries as well as provide additional strength to the framework of the electric vehicle. Furthermore, the structural elements can provide impact resistance to prevent unwanted intrusion into the battery enclosure.

Abstract: A battery enclosure for use in an electric vehicle where the structural support members of the battery enclosure are multi-functional and act to provide support for internally positioned batteries as well as provide additional strength to the framework of the electric vehicle. Furthermore, the structural elements can provide impact resistance to prevent unwanted intrusion into the battery enclosure.

Abstract: Provided are methods and systems for battery pack thermal management, such as heating and cooling of individual batteries arranged into battery packs. The methods and systems use thermal control modules, specifically configured to thermally couple to the side wall and the bottom end of each battery in a battery pack. In some examples, a thermal control module comprises a thermal plate and one or two battery engagement components, connected and thermally coupled to the thermal plate. Each battery engagement component comprises a plurality of battery receiving openings. When the batteries are installed into these openings, the side wall and the bottom end of each battery are thermally coupled to the thermal control module. Thermal fluid is circulated through at least the thermal plate to provide cooling or heating to the batteries without any direct contact between the thermal fluid and the batteries.

Abstract: Provided are methods and systems for battery pack thermal management, such as heating and cooling of individual batteries arranged into battery packs. The methods and systems use thermal control modules, specifically configured to thermally couple to the side wall and the bottom end of each battery in a battery pack. In some examples, a thermal control module comprises a thermal plate and one or two battery engagement components, connected and thermally coupled to the thermal plate. Each battery engagement component comprises a plurality of battery receiving openings.

Abstract: Provided are methods and systems for battery pack thermal management, such as heating and cooling of individual batteries arranged into battery packs. The methods and systems use thermal control modules, specifically configured to thermally couple to the side wall and the bottom end of each battery in a battery pack. In some examples, a thermal control module comprises a thermal plate and one or two battery engagement components, connected and thermally coupled to the thermal plate. Each battery engagement component comprises a plurality of battery receiving openings.

Abstract: A cooling system for a battery cell. In one embodiment, the cooling system includes a wicking material and a first cooling liquid; a battery cell support to hold the battery cell in communication with the wicking material; a first cooling channel having a wall, the wall having an interior and an exterior surface, the interior surface of the wall defining a lumen, the exterior surface of the wall of the first cooling channel in communication with the wicking material; whereby a first cooling fluid is passed through the lumen of the first cooling channel, whereby the first cooling liquid in the wicking material vaporizes in response to heat radiating from the battery cell, and whereby the vaporized first cooling liquid condenses upon contact with the wall of the first cooling channel and is wicked by the wicking material.

Abstract: This disclosure relates to techniques for implementing a cooling system for a vehicle heat-generating component wherein a two-phase coolant flows between a heat sink module and a heat radiator module. The heat radiator module can be mounted at a higher elevation within the vehicle than the heat sink module. High and low temperature fluid paths can fluidly couple the heat sink module and the heat radiator module. The heat sink module can be coupled to a heat-generating component. As the coolant is heated at the heat sink module by heat from the heat-generating component, it can change to a substantially gaseous phase and move, primarily by force of buoyancy, to the heat radiator module via the high temperature fluid path. As the coolant is cooled by the heat radiator module, it can change to a substantially liquid phase and move, primarily by force of gravity, to the heat sink module.

Abstract: This disclosure relates to techniques for implementing a cooling system for a vehicle heat-generating component wherein a two-phase coolant flows between a heat sink module and a heat radiator module. The heat radiator module can be mounted at a higher elevation within the vehicle than the heat sink module. High and low temperature fluid paths can fluidly couple the heat sink module and the heat radiator module. The heat sink module can be coupled to a heat-generating component. As the coolant is heated at the heat sink module by heat from the heat-generating component, it can change to a substantially gaseous phase and move, primarily by force of buoyancy, to the heat radiator module via the high temperature fluid path. As the coolant is cooled by the heat radiator module, it can change to a substantially liquid phase and move, primarily by force of gravity, to the heat sink module.

Abstract: Systems and methods for improving an electric vehicle are disclosed. Systems and methods may include an housing enclosure for an electric vehicle battery module that is configured to include a coolant inlet and a coolant outlet. The housing enclosure may include an upper portion and a lower portion that are coupled together at a mating surface via a gasket. The gasket may provide a long lasting seal that prevents coolant from leaking into or out of the mating surface of the housing enclosure. The systems and methods may include a plurality of electrochemical cells disposed within the housing enclosure.

Abstract: A method of making a printed wiring board (“PWB”) is disclosed. The PWB may be made by forming openings in a substrate. The substrate may be a dielectric substrate. The dielectric substrate may be at least partially uncured. A conductive sheet may be placed on one or both sides of the substrate to cover the openings. The substrate may be cured. The conductive sheet(s) may then be etched to form conductive tabs within the openings. The conductive tabs are free of dielectric material on both sides of the conductive tab. The conductive tabs may then be coupled to terminals of electrochemical cells to form a circuit as desired.

Abstract: Disclosed herein are battery systems for electric vehicles. An electric vehicle may include a first battery. The first battery may be configured to power various low voltage systems. For example, the first battery may provide the power to start the vehicle. The vehicle may include a second battery. The second battery may be configured to power one or more electric motors for propelling the vehicle. The first battery may supply power necessary to engage and/or access the power stored in the second battery. The first battery may include a flexible circuit configured to electrically connect a plurality of battery cells in series and/or in parallel. The flexible circuit may be configured to contact each cell at a plurality of points to ensure that the cells remain connected during the operation of the vehicle.

Abstract: A cooling system for a battery cell. In one embodiment, the cooling system includes a wicking material and a first cooling liquid; a battery cell support to hold the battery cell in communication with the wicking material; a first cooling channel having a wall, the wall having an interior and an exterior surface, the interior surface of the wall defining a lumen, the exterior surface of the wall of the first cooling channel in communication with the wicking material; whereby a first cooling fluid is passed through the lumen of the first cooling channel, whereby the first cooling liquid in the wicking material vaporizes in response to heat radiating from the battery cell, and whereby the vaporized first cooling liquid condenses upon contact with the wall of the first cooling channel and is wicked by the wicking material.