Abstract: In general, one aspect disclosed features an apparatus, comprising: a battery; a resistive load; a switch comprising a first transistor and a second transistor; a resistor; an inductor; and a control circuit; wherein the switch, the resistor, and the inductor are coupled in series between the battery and the resistive load; and wherein the control circuit controls the switch based on a voltage across the resistor. In general, another aspect disclosed features an apparatus, comprising: a battery; a resistive load; a switch; a resistor; an inductor; and a control circuit; wherein the switch, the resistor, and the inductor are coupled in series between the battery and the resistive load; and wherein the control circuit controls the switch based on a voltage across the resistor.

Abstract: An electric vehicle battery pack with a strike shield affixed to its bottom. The strike shield provides structural support to withstand ground strikes without damaging the batteries within the battery pack. The strike shield is a mixed material sandwich bottom plate structure having a composite top layer, a middle core with one or more hollow members adhesively connected or welded together, or a single integrated structure with elongated stiffeners and/or a base member with elongated channels for stiffness, and a composite bottom layer.

Abstract: An electric vehicle battery pack with a strike shield affixed to its bottom. The strike shield provides structural support to withstand ground strikes without damaging the batteries within the battery pack. The strike shield is a mixed material sandwich bottom plate structure having a composite top layer, a middle core with one or more hollow members adhesively connected or welded together, or a single integrated structure with elongated stiffeners and/or a base member with elongated channels for stiffness, and a composite bottom layer.

Abstract: Systems and methods are provided for a high efficiency cold plate system. A high efficiency cold plate system may include an interior surface. A heat source may be configured adjacent to a lower portion of the interior surface. The interior surface may enclose an interior region. The interior surface may also include members extending across the interior surface. The members may be separated by an orifice. The members and interior surface may defined an inlet region and an outlet region. The inlet and outlet regions may be fluidly joined by an orifice separating the members extending across the interior surface. The members may be angled relative to a lower portion of the interior surface. Angling the members may allow the system to constrain and direct fluid flowing through the system to achieve efficient cooling.

Abstract: Systems and methods are provided for a high efficiency cold plate system. A high efficiency cold plate system may include an interior surface. A heat source may be configured adjacent to a lower portion of the interior surface. The interior surface may enclose an interior region. The interior surface may also include members extending across the interior surface. The members may be separated by an orifice. The members and interior surface may defined an inlet region and an outlet region. The inlet and outlet regions may be fluidly joined by an orifice separating the members extending across the interior surface. The members may be angled relative to a lower portion of the interior surface. Angling the members may allow the system to constrain and direct fluid flowing through the system to achieve efficient cooling.

Abstract: A battery system of a vehicle may include a main battery pack, a secondary battery pack, and one or more secondary contactors. The main battery pack is integrated into the vehicle and includes a first plurality of battery cells, a first DC bus coupled to the first plurality of battery cells, and main contactors coupled to the first DC bus to form a switched DC bus. The secondary battery pack includes a second plurality of battery cells, and a second DC bus coupled to the second plurality of battery cells. The second DC bus of the secondary battery pack is electrically coupled to the switched DC bus of the main battery pack via the secondary contactors. In some embodiments, the main battery pack includes control circuitry configured to communicate with control circuitry of the secondary battery pack to manage or monitor coupling of the battery packs.

Abstract: A frame is described for positioning a battery using a vision system to determine at least one weld point on the battery. The frame includes at least one visual reference feature detectable by the vision system. The reference feature is used by the vision system to determine the weld point(s). For example, the at least one visual reference feature includes a pair of stubs that define a line, and the at least one weld point is determined based on the line. In a further example, the pair of stubs correspond to respective batteries, which are arranged adjacent to one another within the frame. In a further example, respective centers of the stubs are lined up along a center line extending from respective centers of respective end faces of the respective batteries. The vision system includes vision circuitry, processing circuitry coupled to the vision circuitry, and a weld system.

Abstract: In general, one aspect disclosed features an apparatus, comprising: a battery; a resistive load; a switch comprising a first transistor and a second transistor; a resistor; an inductor; and a control circuit; wherein the switch, the resistor, and the inductor are coupled in series between the battery and the resistive load; and wherein the control circuit controls the switch based on a voltage across the resistor. In general, another aspect disclosed features an apparatus, comprising: a battery; a resistive load; a switch; a resistor; an inductor; and a control circuit; wherein the switch, the resistor, and the inductor are coupled in series between the battery and the resistive load; and wherein the control circuit controls the switch based on a voltage across the resistor.

Abstract: A battery module is provided. The battery module comprises a plurality of battery cells. Each battery cell comprises a first electrical terminal and a second electrical terminal. The battery module further comprises at least one bi-metallic busbar, e.g., at least one first busbar. The at least one first busbar comprises a metallic part, e.g., a first aluminum part, electrically coupled to the first electrical terminals of a first group of the plurality of battery cells. The first busbar further comprises another metallic part, e.g., a first copper part. The first copper part comprises a first interface part electrically coupled to the first aluminum part. The first copper part comprises a first terminal part configured to be electrically coupled to a conductor external to the battery module.

Abstract: A high voltage distribution system is provided with multiple fuses. The high voltage distribution system includes multiple laminated busbars that are electrically coupled to a battery and to the multiple fuses. Busbars are electrically coupled to the one or more fuses via electrical connections between the busbars and the fuses. The electrical connections can pass through other busbars without having an electrical coupling to the other busbars. An insulating layer may be used between the busbars to prevent overcurrent events. The configuration, size, and position of each busbar is selected based on the electrical requirements of components that are electrically coupled to the busbar and based on the prevention of overcurrent events.

Abstract: A circuit protection system is provided herein that minimizes the disconnection time of a circuit while protecting other electrical components. Some configurations comprise a set of parallel circuit interruption devices, each connected in series with respective fuses. A control device sets a state of the circuit interruption device based on a current of the circuit. Under certain current loads, the circuit is interrupted without causing a fuse to blow. Under other current loads, the circuit is interrupted by having one or more fuses blow.

Abstract: An interconnect is disclosed that opens a battery circuit when an access cover is removed. The interconnect includes a single installed position, and does not include any throw positions to avoid ambiguity. The interconnect includes a conductive element that closes the battery circuit when the interconnect is installed. The access cover cannot be removed when the interconnect is installed, because the interconnect includes at least one mechanical feature that prevents removal of the access cover. In some instances, the interconnect is integrated into the access cover, such that when the cover is removed, the circuit is opened necessarily during removal. The interconnect interface may include blades, pins, or other electrically conducting elements. The interconnect is arranged in the battery system away from power electronics and other components that may interface to an electrical load, thus providing an added measure of safety when the access cover is off.

Abstract: Electric vehicle battery pack frames constructed with extruded aluminum side and cross members. Such frames are significantly stronger than conventional cast aluminum frames, while also being much lighter than steel frames. Cross members may be affixed to side members with extruded aluminum brackets. Side members of differing lengths may be employed, to make battery pack frames of differing sizes in modular manner. Battery pack lids and bottom panels may be removably affixed to the frame such as with bolts, for improved serviceability.

Abstract: A battery module is provided. The battery module comprises a plurality of battery cells. Each battery cell comprises a first electrical terminal and a second electrical terminal. The battery module further comprises at least one bi-metallic busbar, e.g., at least one first busbar. The at least one first busbar comprises a metallic part, e.g., a first aluminum part, electrically coupled to the first electrical terminals of a first group of the plurality of battery cells. The first busbar further comprises another metallic part, e.g., a first copper part. The first copper part comprises a first interface part electrically coupled to the first aluminum part. The first copper part comprises a first terminal part configured to be electrically coupled to a conductor external to the battery module.

Abstract: A circuit protection system is provided herein that minimizes the disconnection time of a circuit while protecting other electrical components. Some configurations comprise a set of parallel circuit interruption devices, each connected in series with respective fuses. A control device sets a state of the circuit interruption device based on a current of the circuit. Under certain current loads, the circuit is interrupted without causing a fuse to blow. Under other current loads, the circuit is interrupted by having one or more fuses blow.

Abstract: A high voltage distribution system is provided with multiple fuses. The high voltage distribution system includes multiple laminated busbars that are electrically coupled to a battery and to the multiple fuses. Busbars are electrically coupled to the one or more fuses via electrical connections between the busbars and the fuses. The electrical connections can pass through other busbars without having an electrical coupling to the other busbars. An insulating layer may be used between the busbars to prevent overcurrent events. The configuration, size, and position of each busbar is selected based on the electrical requirements of components that are electrically coupled to the busbar and based on the prevention of overcurrent events.

Abstract: Systems and methods that provide an improved mechanism for attaching a sensor wire to a bus bar in a battery module are disclosed. A battery module according to the present disclosure may include a bus bar comprising a rivet hole and a plurality of battery cells electrically coupled to the bus bar. The battery module may also include a sensor wire comprising a terminal end, as well as a blind rivet passing through the rivet hole of the bus bar and coupling the bus bar to the terminal end of the sensor wire. Attaching the sensor wire to the bus bar with a blind rivet may provide one or more of the following mechanical advantages: fast assembly, robustness for low power applications, elimination of the need to wait for an adhesive to cure, and elimination of the need for double-sided access of the bus bar.

Abstract: An interconnect is disclosed that opens a battery circuit when an access cover is removed. The interconnect includes a single installed position, and does not include any throw positions to avoid ambiguity. The interconnect includes a conductive element that closes the battery circuit when the interconnect is installed. The access cover cannot be removed when the interconnect is installed, because the interconnect includes at least one mechanical feature that prevents removal of the access cover. In some instances, the interconnect is integrated into the access cover, such that when the cover is removed, the circuit is opened necessarily during removal. The interconnect interface may include blades, pins, or other electrically conducting elements. The interconnect is arranged in the battery system away from power electronics and other components that may interface to an electrical load, thus providing an added measure of safety when the access cover is off.

Abstract: Electric vehicle battery pack frames constructed with extruded aluminum side and cross members. Such frames are significantly stronger than conventional cast aluminum frames, while also being much lighter than steel frames. Cross members may be affixed to side members with extruded aluminum brackets. Side members of differing lengths may be employed, to make battery pack frames of differing sizes in modular manner. Battery pack lids and bottom panels may be removably affixed to the frame such as with bolts, for improved serviceability.

Abstract: A drain system is described for allowing fluid to drain from a battery pack while maintaining structural integrity of the battery pack. A frame of the battery pack is comprised of several retaining members in which valves are disposed to allow fluid to exit the battery pack. The valves are positioned such that forces normally experienced while driving a vehicle, such as acceleration, deceleration, and turning forces, cause the fluid to flow toward and through the valves.