Abstract: System and methods for estimating a state if a fuse are presented. In some embodiments, the disclosed systems and methods may be utilized in connection with estimating a state of a fuse associated with a manual service disconnect associated with an energy storage system included in a vehicle. Consistent with embodiments disclosed herein, a current event counting-based method utilizing one or more weighted time data buckets associated with various current levels may be used in connection with estimating MSD fuse life. In some embodiments, a MSD fuse end-of-service life signal may be triggered when a total time associated in the weighted time data buckets exceed a threshold value.

Abstract: A battery pack, a device for sensing individual battery voltages in a battery pack and protecting the battery pack in the event of a circuit-breaking event, and a method for forming an encapsulant for the voltage-sensing circuit for use in a battery-powered automobile propulsion system. The battery pack includes numerous voltage sensing circuits with surface-mounted fuses and an encapsulant formed around each of the fuses. The encapsulant is robust enough to provide environmental isolation of the surface-mounted fuse such that the tendency of the fuse to form short-circuit connections to adjacent circuits is avoided under both normal battery pack operation and after a condition where the battery pack is compromised. The precursor to the encapsulant is made from a multiple layers of a traditional thin coating material or a single layer of a high-viscosity fluid to help maintain a minimum coating thickness around all exposed portions of the surface-mounted fuse, including the breech-prone corners.

Abstract: A battery pack, a device for sensing individual battery voltages in a battery pack and protecting the battery pack in the event of a circuit-breaking event, and a method for forming an encapsulant for the voltage-sensing circuit for use in a battery-powered automobile propulsion system. The battery pack includes numerous voltage sensing circuits with surface-mounted fuses and an encapsulant formed around each of the fuses. The encapsulant is robust enough to provide environmental isolation of the surface-mounted fuse such that the tendency of the fuse to form short-circuit connections to adjacent circuits is avoided under both normal battery pack operation and after a condition where the battery pack is compromised. The precursor to the encapsulant is made from a multiple layers of a traditional thin coating material or a single layer of a high-viscosity fluid to help maintain a minimum coating thickness around all exposed portions of the surface-mounted fuse, including the breech-prone corners.

Abstract: System and methods for estimating a state if a fuse are presented. In some embodiments, the disclosed systems and methods may be utilized in connection with estimating a state of a fuse associated with a manual service disconnect associated with an energy storage system included in a vehicle. Consistent with embodiments disclosed herein, a current event counting-based method utilizing one or more weighted time data buckets associated with various current levels may be used in connection with estimating MSD fuse life. In some embodiments, a MSD fuse end-of-service life signal may be triggered when a total time associated in the weighted time data buckets exceed a threshold value.

Abstract: A battery module for an electric vehicle includes an auxiliary power module (APM) and at least one battery pack assembly. The battery pack assembly includes a plurality of battery frames, each with at least one battery cell disposed within it, and a plurality of cooling plates, each in thermal communication with at least one battery cell. The cooling plates have an inlet and an outlet connected by at least one coolant channel through which coolant is circulated to cool the battery cells. The APM may also require cooling, in which case the battery module may further include at least one additional cooling plate in thermal communication with the APM. The APM and the battery pack assembly are held together under compression such that they may share a common cooling system, and coolant may flow through the APM and/or the battery pack assembly to the cooling plates.

Abstract: A battery cell module includes a battery cell, a sliding repeating element, and a guide rail. The repeating element is disposed adjacent the battery cell. A gap is defined between the battery cell and the repeating element. The repeating element has a main body with at least one spacer coupled thereto. The guide rail cooperates with the at least one spacer and permits the repeating element to move with an expansion of the battery cell. The cooperation of the guide rail with the at least one spacer thereby militates against an overcompression of the battery cell.

Abstract: A battery module for an electric vehicle includes an auxiliary power module (APM) and at least one battery pack assembly. The battery pack assembly includes a plurality of battery frames, each with at least one battery cell disposed within it, and a plurality of cooling plates, each in thermal communication with at least one battery cell. The cooling plates have an inlet and an outlet connected by at least one coolant channel through which coolant is circulated to cool the battery cells. The APM may also require cooling, in which case the battery module may further include at least one additional cooling plate in thermal communication with the APM. The APM and the battery pack assembly are held together under compression such that they may share a common cooling system, and coolant may flow through the APM and/or the battery pack assembly to the cooling plates.

Abstract: A battery cell module includes a battery cell, a sliding repeating element, and a guide rail. The repeating element is disposed adjacent the battery cell. A gap is defined between the battery cell and the repeating element. The repeating element has a main body with at least one spacer coupled thereto. The guide rail cooperates with the at least one spacer and permits the repeating element to move with an expansion of the battery cell. The cooperation of the guide rail with the at least one spacer thereby militates against an overcompression of the battery cell.