Abstract: Provided herein is a power converter component to power a drive unit of an electric vehicle drive system. The power converter component includes an inverter module formed having three half-bridge modules arranged in a triplet configuration for electric vehicle drive systems. Positive inputs, negative inputs, and output terminals of the different half-bridge inverter modules are aligned with each other. The inverter module includes a positive bus-bar coupled with the positive inputs and a negative bus-bar coupled with the negative inputs of the half-bridge inverter modules. The positive bus-bar is positioned adjacent to and parallel with the negative bus-bar. The inverter module can be coupled with a drive train unit of the electric vehicle and provide three phase voltages to the drive train unit. Each of the half bridge modules can generate a single phase voltage and three half-bridge modules arranged in a triplet configuration can provide three phase voltages.

Abstract: Provided herein is a power converter component to power a drive unit of an electric vehicle drive system. The power converter component includes an inverter module formed having three half-bridge modules arranged in a triplet configuration for electric vehicle drive systems. Positive inputs, negative inputs, and output terminals of the different half-bridge inverter modules are aligned with each other. The inverter module includes a positive bus-bar coupled with the positive inputs and a negative bus-bar coupled with the negative inputs of the half-bridge inverter modules. The positive bus-bar is positioned adjacent to and parallel with the negative bus-bar. The inverter module can be coupled with a drive train unit of the electric vehicle and provide three phase voltages to the drive train unit. Each of the half bridge modules can generate a single phase voltage and three half-bridge modules arranged in a triplet configuration can provide three phase voltages.

Abstract: Provided herein is a power converter component to power a drive unit of an electric vehicle drive system. The power converter component includes an inverter module formed having three half-bridge modules arranged in a triplet configuration for electric vehicle drive systems. Positive inputs, negative inputs, and output terminals of the different half-bridge inverter modules are aligned with each other. The inverter module includes a positive bus-bar coupled with the positive inputs and a negative bus-bar coupled with the negative inputs of the half-bridge inverter modules. The positive bus-bar is positioned adjacent to and parallel with the negative bus-bar. The inverter module can be coupled with a drive train unit of the electric vehicle and provide three phase voltages to the drive train unit. Each of the half bridge modules can generate a single phase voltage and three half-bridge modules arranged in a triplet configuration can provide three phase voltages.

Abstract: Provided herein are power converter of a drive unit for an electric vehicle. The power converter includes an inverter having a first transistor, a second transistor, and a capacitor, and a laminated bus-bar having a positive bus-bar segment, a negative bus-bar segment and a phase bus-bar segment. The positive bus-bar segment, the negative bus-bar segment, and the phase bus-bar segment can be disposed about the capacitor to form a lead frame coupled with the capacitor. The lead frame can include a first lead coupled with the first transistor. The first lead can include portions of the positive bus-bar segment and the phase bus-bar segment. The lead frame can include a second lead coupled with the second transistor. The second lead can include portions of the negative bus-bar segment and the phase bus-bar segment.

Abstract: Provided herein are power converter of a drive unit for an electric vehicle. The power converter includes an inverter having a first transistor, a second transistor, and a capacitor, and a laminated bus-bar having a positive bus-bar segment, a negative bus-bar segment and a phase bus-bar segment. The positive bus-bar segment, the negative bus-bar segment, and the phase bus-bar segment can be disposed about the capacitor to form a lead frame coupled with the capacitor. The lead frame can include a first lead coupled with the first transistor. The first lead can include portions of the positive bus-bar segment and the phase bus-bar segment. The lead frame can include a second lead coupled with the second transistor. The second lead can include portions of the negative bus-bar segment and the phase bus-bar segment.

Abstract: Provided herein is an inverter module that can include a first inverter cell and a second inverter cell, each including at least one transistor device, and a cold plate placed in contact with or proximate to the at least one transistor device. The cold plate can have a coolant channel through the cold plate. A connector can connect a coolant outlet of the cold plate of the first inverter cell to a coolant inlet of the cold plate of the second inverter cell in series, to form a continuous channel that extends from the first coolant inlet of the cold plate of the first inverter cell into the coolant channel of the cold plate of the second inverter cell. The coolant inlet of the cold plate of the first inverter cell can receive coolant fluid into the continuous channel.

Abstract: A laminated bus bar of an inverter module to power an electric vehicle is provided. The laminated bus bar can include a first insulating layer and a current layer disposed over the first insulting layer. The current layer can include an output terminal. The laminated bus bar can include a second insulating layer disposed over the current layer. The laminated bus bar can include a third insulating layer disposed over the second insulating layer. The laminated bus bar can include a first polarity (e.g., negative) layer disposed over the third insulating layer. The first polarity layer can include a first polarity (e.g., negative) input terminal. The laminated bus bar can include a fourth insulating layer disposed over the first polarity layer. The laminated bus bar can include a second polarity (e.g., positive) layer disposed over the fourth insulating layer and that includes a second polarity (e.g., positive) input terminal.

Abstract: Provided herein is a power converter component to power a drive unit of an electric vehicle drive system. The power converter component includes an inverter module formed having three half-bridge modules arranged in a triplet configuration for electric vehicle drive systems. Positive inputs, negative inputs, and output terminals of the different half-bridge inverter modules are aligned with each other. The inverter module includes a positive bus-bar coupled with the positive inputs and a negative bus-bar coupled with the negative inputs of the half-bridge inverter modules. The positive bus-bar is positioned adjacent to and parallel with the negative bus-bar. The inverter module can be coupled with a drive train unit of the electric vehicle and provide three phase voltages to the drive train unit. Each of the half bridge modules can generate a single phase voltage and three half-bridge modules arranged in a triplet configuration can provide three phase voltages.

Abstract: Systems, methods, and apparatuses associated with energy storage are provided. A circuit board can include a first contact patch to electrically couple with a first conductive layer of an integrated current collector of a battery block to connect with first polarity terminals of battery cells. The circuit board can include a second contact patch to electrically couple with a second conductive layer of the integrated current collector of the battery block to connect with second polarity terminals of battery cells. The circuit board can include a third contact patch to connect to a thermistor to measure a temperature of the battery block. The circuit board can include embedded conductive traces, and can include a connector to electrically couple the contact patches via the embedded conductive traces to a battery monitoring unit (BMU) to relay a signal indicative of a characteristic of a component of the battery block.

Abstract: Systems and methods to power electric vehicles are disclosed. A battery pack to power an electric vehicle is provided. The battery pack residing in the electric vehicle. The battery pack can include a plurality of battery modules. Each of the plurality of battery modules can include a plurality of battery blocks. A first battery block can include a plurality of cylindrical battery cells. Each of the plurality of cylindrical battery cells can have a pair of battery cell terminals and can have a voltage of up to 5 volts across the pair of battery cell terminals. The plurality of cylindrical battery cells can be electrically connected in parallel within the first battery block. Each cylindrical battery cell of the plurality of cylindrical battery cells can be spatially separated from each of at least one adjacent cylindrical battery cell within the first battery block by less than 2 millimeter (mm).

Abstract: Systems, methods, devices, and apparatuses associate with energy storage are provided. An apparatus can include a battery block with battery cells disposed therein. The apparatus can include an integrated current collector to electrically couple the battery cells in parallel. The integrated current collector can have a first conductive layer to connect with first polarity terminals of the battery cells, a second conductive layer to connect with second polarity terminals of the battery cells, and a circuit board layer parallel to the two conductive layers. The apparatus can include trace lines each formed on the circuit board layer and connected to the two conductive layers. The apparatus can include a battery monitoring unit (BMU) incorporated on the circuit board layer. The BMU can have inputs coupled with the two conductive layers to obtain a signal indicative of a characteristic of the battery block.

Abstract: Systems and methods for a battery pack to power an electric vehicle are provided. The battery pack can include a plurality of battery modules having a plurality of battery blocks. The battery blocks can include a plurality of cylindrical battery cells. A first current collector can include a conductive layer to couple the first current collector with positive terminals of the plurality of cylindrical battery cells. A second current collector can include a conductive layer to couple the second current collector with negative terminals of the plurality of cylindrical battery cells. The first current collector, second current collector, and an isolation layer can include a plurality of apertures to expose the positive terminals of the plurality of cylindrical battery cells. The positive terminals can extend through the plurality of apertures to couple with the conductive layer of the first current collector.

Abstract: Systems and methods to power an electric vehicle are provided. The system can include a battery pack having a plurality of battery modules, each of the of battery modules can include a plurality of battery blocks. The battery blocks can include a plurality of cylindrical battery cells. An integrated current collector device can be formed in a single structure and coupled with the plurality of cylindrical battery cells. The integrated current collector device can include a first current collector to couple with positive terminals of the cylindrical battery cells at first ends of the cylindrical battery cells and a second current collector to couple with negative terminals of the cylindrical battery cells at the first ends of the cylindrical battery cells. An isolation layer can be disposed between the first current collector and the second current collector to electrically isolate the first current collector from the second current collector.

Abstract: Systems and methods of controlling temperature in energy storage units. The system can include energy storage units disposed in an electric vehicle. The system can include cold plates disposed in the electric vehicle. Each cold plate can be thermally coupled with an energy storage unit to transfer heat using a coolant. Each cold plate can have an inlet to receive the coolant from an inlet manifold, an outlet to release liquid to an outlet manifold, and a control valve coupled to at least one of the inlet and the outlet. The system can include a battery management system (BMS) connected with the energy storage units. The BMS can determine, for each cold plate, a target flow rate for the coolant using a characteristic of the energy storage unit. The BMS can send, to each cold plate, a signal to control the control valve in accordance with the target flow rate.

Abstract: Apparatuses, systems, and methods of controlling of an energy storage unit are detailed herein. A cold plate can be thermally coupled with an energy storage unit for powering the electric vehicle. The cold plate can have a bottom layer. The bottom layer can have a channel spanning across a top surface of the bottom layer to circulate coolant to transfer heat away from the energy storage unit. The top layer can be flush with a bottom surface of the energy storage unit. The top layer can define openings each extending between the top surface and the bottom surface. The cold plate can have inserts sealing the openings. The inserts can have a melting temperature lower than a melting temperature of the top layer to expose at least one opening when heated the melting temperature to allow release of the coolant from the channel onto the energy storage unit.

Abstract: Systems and methods for interconnecting battery blocks are disclosed. A plurality of battery blocks can include a first battery block and a second battery block. Each battery block can include a plurality of battery cells electrically connected and physically arranged to form a battery module for storing energy. A plurality of ribbonbond interconnects are produced to electrically connect a current collector of the first battery block with a current collector of the second battery block. Each ribbonbond interconnect can comprise a metallic strip to provide a flexible physical connection between the first battery block and the second battery block to allow movement between the first battery block and the second battery block. Each ribbonbond interconnect can break an electrical connection between the first battery block and the second battery block if an electrical current in the corresponding ribbonbond interconnect exceeds a predefined threshold.

Abstract: Provided herein is an electric vehicle battery pack system that powers electric vehicles. The electric vehicle battery pack system can include a battery pack to power an electric vehicle. The battery pack can reside in the electric vehicle and include a plurality of battery modules. The plurality of battery modules can include a plurality of battery blocks. The battery blocks can have a plurality of cylindrical battery cells connected in parallel. A battery module of the plurality of battery modules can include a battery monitoring unit. The battery module can include a cold plate coupled with the first battery module and the battery monitoring unit. The cold plate can receive control signals from the battery monitoring unit. The control signals can identify a battery module and identify a climate control parameter for the battery module. The cold plate can apply the climate control parameter to the battery module.

Abstract: A power supply system is disclosed that includes a first interleaved power supply, a second interleaved power supply, and a common electromagnetic interference filter. The common electromagnetic interference filter is configured to provide DC power from a DC power source to both the first interleaved power supply and the second interleaved power supply. In one example, the common electromagnetic interference filter comprises a localized filter stage configured to receive DC power from the DC power source, and a distributed filter stage configured to receive DC power from the localized filter stage. The distributed filter stage includes a first set of common mode capacitors electrically connected to and physically proximate input power lines of the first interleaved power supply, and a second set of common mode capacitors electrically connected to and physically proximate input power lines of the second interleaved power supply.

Abstract: A power supply system suitable for use by an aircraft is disclosed. The power system converts power from an unregulated DC power source to multiple AC and DC voltage outputs. The power supply system comprises an interleaved buck converter, and interleaved full-bridge converter, an interleaved inverter, and a control system. In one configuration, the interleaved inverter uses high-voltage DC generated by the interleaved four-bridge converter as its power input to generate a high-voltage AC output.

Abstract: A power supply system suitable for use by an aircraft is disclosed. The power system converts power from an unregulated DC power source to multiple AC and DC voltage outputs. The power supply system comprises an interleaved buck converter, and interleaved full-bridge converter, an interleaved inverter, and a control system. In one configuration, the interleaved inverter uses high-voltage DC generated by the interleaved four-bridge converter as its power input to generate a high-voltage AC output.