Abstract: An energy storage pack includes a coolant inlet manifold, a coolant outlet manifold, and a plurality of thermal-exchange tubes extending between the coolant inlet manifold and the coolant outlet manifold to exchange heat between coolant passing through the plurality of thermal-exchange tubes and a plurality of battery cells mounted adjacent to and among the plurality of thermal-exchange tubes within the energy storage pack. In one embodiment, at least one of coolant inlet manifold and the coolant outlet manifold includes a plurality of thermal-exchange tube terminating structures and a plurality of hose segments intercoupling the plurality of thermal-exchange tube terminating structures. The energy storage pack may further include a coolant inlet opening located on the coolant inlet manifold and a coolant outlet opening located on the coolant outlet manifold.

Abstract: Impact protection structures for vehicles are described. An impact protection structure includes a support structure of the vehicle, an interior rail coupled to the support structure, and an exterior rail coupled to the interior rail. The exterior rail has an inboard boundary wall positioned between an upper mounting region and a lower mounting region. The upper and the lower exterior mounting region of the exterior rail are coupled to an upper and a lower mounting region of the interior rail. At least a portion of the inboard boundary wall is spaced apart from an outboard wall of the interior rail such that when the exterior rail is impacted by a blunt-object barrier, the inboard boundary wall of the exterior rail deforms, thereby damping energy of the impact at the exterior rail and arresting crack propagation between the exterior rail and the interior rail.

Abstract: An energy storage pack includes a coolant inlet manifold, a coolant outlet manifold, and a plurality of thermal-exchange tubes extending between the coolant inlet manifold and the coolant outlet manifold to exchange heat between coolant passing through the plurality of thermal-exchange tubes and a plurality of battery cells mounted adjacent to and among the plurality of thermal-exchange tubes within the energy storage pack. In one embodiment, at least one of coolant inlet manifold and the coolant outlet manifold includes a plurality of thermal-exchange tube terminating structures and a plurality of hose segments intercoupling the plurality of thermal-exchange tube terminating structures. The energy storage pack may further include a coolant inlet opening located on the coolant inlet manifold and a coolant outlet opening located on the coolant outlet manifold.

Abstract: An impact protection structure for a vehicle impacting a blunt-object barrier includes a support structure of the vehicle, an energy absorbing rail coupled to the support structure, and a localized energy dissipation structure. The energy absorbing rail extends an energy absorbing rail length and includes a plurality of lumens. The localized energy dissipation structure extends a localized energy dissipation structure length less than the energy absorbing rail length.

Abstract: Impact protection structures for vehicles are described. An impact protection structure includes a support structure of the vehicle, an interior rail coupled to the support structure, and an exterior rail coupled to the interior rail. The exterior rail has an inboard boundary wall positioned between an upper mounting region and a lower mounting region. The upper and the lower exterior mounting region of the exterior rail are coupled to an upper and a lower mounting region of the interior rail. At least a portion of the inboard boundary wall is spaced apart from an outboard wall of the interior rail such that when the exterior rail is impacted by a blunt-object barrier, the inboard boundary wall of the exterior rail deforms, thereby damping energy of the impact at the exterior rail and arresting crack propagation between the exterior rail and the interior rail.

Abstract: Impact protection structures for vehicles are described. An impact protection structure includes a support structure of the vehicle, an interior rail coupled to the support structure, and an exterior rail coupled to the interior rail. The exterior rail has an inboard boundary wall positioned between an upper mounting region and a lower mounting region. The upper and the lower exterior mounting region of the exterior rail are coupled to an upper and a lower mounting region of the interior rail. At least a portion of the inboard boundary wall is spaced apart from an outboard wall of the interior rail such that when the exterior rail is impacted by a blunt-object barrier, the inboard boundary wall of the exterior rail deforms, thereby damping energy of the impact at the exterior rail and arresting crack propagation between the exterior rail and the interior rail.

Abstract: An impact protection structure for a vehicle impacting a blunt-object barrier includes a support structure of the vehicle, an energy absorbing rail coupled to the support structure, and a localized energy dissipation structure. The energy absorbing rail extends an energy absorbing rail length and includes a plurality of lumens. The localized energy dissipation structure extends a localized energy dissipation structure length less than the energy absorbing rail length.

Abstract: An impact protection structure for a vehicle impacting a blunt-object barrier includes a support structure of the vehicle, an energy absorbing rail coupled to the support structure, and a localized energy dissipation structure. The energy absorbing rail extends an energy absorbing rail length and includes a plurality of lumens. The localized energy dissipation structure extends a localized energy dissipation structure length less than the energy absorbing rail length.

Abstract: An impact protection structure for a vehicle impacting a blunt-object barrier includes a support structure of the vehicle, an energy absorbing rail coupled to the support structure, and a localized energy dissipation structure. The energy absorbing rail extends an energy absorbing rail length and includes a plurality of lumens. The localized energy dissipation structure extends a localized energy dissipation structure length less than the energy absorbing rail length.

Abstract: Impact protection structures for vehicles are described. An impact protection structure includes a support structure of the vehicle, an interior rail coupled to the support structure, and an exterior rail coupled to the interior rail. The exterior rail has an inboard boundary wall positioned between an upper mounting region and a lower mounting region. The upper and the lower exterior mounting region of the exterior rail are coupled to an upper and a lower mounting region of the interior rail. At least a portion of the inboard boundary wall is spaced apart from an outboard wall of the interior rail such that when the exterior rail is impacted by a blunt-object barrier, the inboard boundary wall of the exterior rail deforms, thereby damping energy of the impact at the exterior rail and arresting crack propagation between the exterior rail and the interior rail.

Abstract: A method and apparatus for simplifying battery pack assembly that allows inspection of the cell-to-housing bonding region is provided. In particular, a battery pack housing member is provided that includes an interior surface that partially defines the interior region of the battery pack and that includes a plurality of cell mounting wells and an exterior surface that includes a plurality of bonding wells. Adhesive introduced into the bonding wells forms a mechanical bond between an exterior surface of a cell introduced into an adjacent cell mounting well and the housing member.

Abstract: An apparatus for simplifying battery pack encapsulation is provided. The battery pack includes a pair of complementary housing members with each housing member including a plurality of cell constraints into which the ends of corresponding battery cells are inserted during assembly. One or both housing members also include at least one, and preferably a plurality, of raised encapsulant injection ports. The raised encapsulant injection ports are designed to extend above the surface of the respective housing members and beyond the injected encapsulation material, thus ensuring that the ports remain open after encapsulation material injection.

Abstract: An apparatus for simplifying battery pack encapsulation is provided. The battery pack includes a pair of complementary housing members with each housing member including a plurality of cell constraints into which the ends of corresponding battery cells are inserted during assembly. One or both housing members also include at least one, and preferably a plurality, of raised encapsulant injection ports. The raised encapsulant injection ports are designed to extend above the surface of the respective housing members and beyond the injected encapsulation material, thus ensuring that the ports remain open after encapsulation material injection.

Abstract: A method and apparatus for simplifying battery pack encapsulation is provided. The battery pack includes a pair of complementary housing members with each housing member including a plurality of cell constraints into which the ends of corresponding battery cells are inserted during assembly. One or both housing members also include at least one, and preferably a plurality, of raised encapsulant injection ports. The raised encapsulant injection ports are designed to extend above the surface of the respective housing members and beyond the injected encapsulation material, thus ensuring that the ports remain open after encapsulation material injection.

Abstract: One embodiment includes a bottom clamshell and a top clamshell sandwiching a first battery and a second battery, with a fill port extending from a top surface of the top clamshell through to the bottom surface of the top clamshell and to a space between the first and second batteries. The embodiment includes a protrusion coupled to the top clamshell proximate to the fill port and extending into the space, wherein the protrusion at least partially occludes a direct path through the fill port to the space.

Abstract: A method and apparatus for simplifying battery pack assembly that allows inspection of the cell-to-housing bonding region is provided. In particular, a battery pack housing member is provided that includes an interior surface that partially defines the interior region of the battery pack and that includes a plurality of cell mounting wells and an exterior surface that includes a plurality of bonding wells. Adhesive introduced into the bonding wells forms a mechanical bond between an exterior surface of a cell introduced into an adjacent cell mounting well and the housing member.

Abstract: A system for optimizing battery pack charging is provided. In this system, during charging the coupling of auxiliary systems (e.g., battery cooling systems) to the external power source are delayed so that the battery pack charge rate may be optimized, limited only by the available power. Once surplus power is available, for example as the requirements of the charging system decrease, the auxiliary system or systems may be coupled to the external power source without degrading the performance of the charging system.

Abstract: The adverse effects of the dielectric material covering the lateral outer surface of a conventional battery are eliminated by replacing it with a dielectric barrier that covers less than 20 percent of the lateral outer surface of the cell case; more preferably less than 15 percent of the lateral outer surface of the cell case; still more preferably less than 10 percent of the lateral outer surface of the cell case; and yet still more preferably less than 5 percent of the lateral outer surface of the cell case. The dielectric barrier may be shrunk-fit, bonded, friction-fit or otherwise held in place. An electrically insulating disk may be interposed between the dielectric barrier and the end edge portion of the cell case.

Abstract: A method and apparatus for simplifying battery pack encapsulation is provided. The battery pack includes a pair of complementary housing members with each housing member including a plurality of cell contraints into which the ends of corresponding battery cells are inserted during assembly. One or both housing members also include at least one, and preferably a plurality, of raised encapsulant injection ports. The raised encapsulant injection ports are designed to extend above the surface of the respective housing members and beyond the injected encapsulation material, thus ensuring that the ports remain open after encapsulation material injection.

Abstract: A system for optimizing battery pack charging is provided. In this system, during charging the coupling of auxiliary systems (e.g., battery cooling systems) to the external power source are delayed so that the battery pack charge rate may be optimized, limited only by the available power. Once surplus power is available, for example as the requirements of the charging system decrease, the auxiliary system or systems may be coupled to the external power source without degrading the performance of the charging system.