Abstract: Methods and systems are provided for managing multi-battery systems, such as those utilized in an electric vehicle. Multi-battery systems comprise batteries providing power in parallel, thereby making each battery available to the vehicle and avoiding the weight of transporting a backup battery. The methods and systems provided allow for a fault in one battery, in a parallel configuration with at least one other battery, to be detected and managed.

Abstract: Methods and systems are disclosed for controlling heat within a junction box. The disclosure relates to the use of phase change materials to manage heat generation in a junction box of a vehicle.

Abstract: Methods and systems provide for the manufacture of a cylindrical battery cell case that is changed from steel (or nickel-plated steel) to aluminum. With this change, spot welding the copper tab from the anode to the aluminum case will result in the copper and aluminum corroding over time—leading to early battery failure. To manufacture the battery with the aluminum case, one or more manufacturing changes are made including one or more of: 1. changing the polarity of the battery to spot weld the copper tab to a steel top of the battery; 2. coating the copper tab with a second material to prevent corrosion; and/or, 3. use a different welding method (e.g., a friction stir weld) to fuse the copper tab to the aluminum case.

Abstract: A vehicle includes a first coolant pump, a first set of coolant plumbing coupled with the first coolant pump and a first set of one or more thermal sources (the first coolant pump operates to circulate coolant through the first set of coolant plumbing to the first set of one or more thermal sources), a second coolant pump, a second set of coolant plumbing coupled with the second coolant pump and a second set of one or more thermal sources (the second coolant pump operates to circulate coolant through the second set of coolant plumbing to the second set of one or more thermal sources) and a plurality of valves coupled with the first set of coolant plumbing and the second set of coolant plumbing. The plurality of valves operates in a plurality of modes to redirect coolant flow through the first set of coolant plumbing and the second set of coolant plumbing.

Abstract: Methods and systems are disclosed for controlling heat within a junction box. The disclosure relates to the use of phase change materials to manage heat generation in a junction box of a vehicle.

Abstract: A power module for a vehicle includes a bidirectional voltage converter to i) convert a first voltage to a second voltage and convert the second voltage back to the first voltage, and ii) convert the first voltage to a third voltage and convert the third voltage back to the first voltage. The power module includes one or more power sources coupled to the bidirectional voltage converter and to supply power to auxiliary components of the vehicle. The power module includes a controller to control the bidirectional voltage converter and the one or more power sources. The first voltage is for supplying power to a powertrain of the vehicle, and the second voltage and the third voltage are for supplying power to the one or more power sources.

Abstract: A power module for a vehicle includes a first bidirectional voltage converter to convert a first voltage to a second voltage and convert the second voltage back to the first voltage. The power module includes a second bidirectional voltage converter to convert the first voltage to a third voltage and convert the third voltage back to the first voltage. The power module includes a first battery coupled to the first bidirectional voltage converter to receive the second voltage, and a second battery coupled to the second bidirectional voltage converter to receive the third voltage. The power module includes a controller to control the first and second bidirectional voltage converters and the first and second batteries. The first voltage is for supplying power to a powertrain of the vehicle. The second voltage and the third voltage are for supplying power to the first and second batteries, respectively.

Abstract: Embodiments of the present disclosure are directed to providing temporary, additional cooling to one or more elements of the vehicle on an as needed basis, e.g., under extreme conditions, when additional cooling is required or predicted to be needed, etc. According to one embodiment, the RC can be “overclocked” or “supercharged” to provide short-term, high output cooling performance under such conditions. For example, if the cooling system is a 10 kW system, it is increased to 15 kW for a short time period by increasing the electrical current and/or frequency to increase the torque and/or speed of the motor driving the RC. According to one embodiment, the cooling system can also be adapted to more effectively utilize the available cooling capacity, either the standard capacity to temporarily increased capacity, by directing the air or liquid coolant to one or more components in need of extra cooling.

Abstract: Systems of an autonomous vehicle and the operations thereof are provided. During travel of an autonomous vehicle, the autonomous vehicle, the autonomous vehicle can determine a charge is needed. Within the planned path of travel, the autonomous vehicle can determine when the autonomous vehicle may arrive at a charging station, what destinations are planned after reaching the charging station, the current temperature of the battery (and the temperature of the surroundings), the weather conditions at the charging station, etc. Based on these determinations and/or calculations, the autonomous vehicle can precondition the battery before the autonomous vehicle arrives at the charging station, for example, the autonomous vehicle starts cooling the battery at a quicker than normal rate so that the autonomous vehicle arrives at the charging station with the battery at the coldest possible temperature.

Abstract: Embodiments of the present disclosure are directed to providing temporary, additional cooling to one or more elements of the vehicle on an as needed basis, e.g., under extreme conditions, when additional cooling is required or predicted to be needed, etc. According to one embodiment, the RC can be “overclocked” or “supercharged” to provide short-term, high output cooling performance under such conditions. For example, if the cooling system is a 10 kW system, it is increased to 15 kW for a short time period by increasing the electrical current and/or frequency to increase the torque and/or speed of the motor driving the RC. According to one embodiment, the cooling system can also be adapted to more effectively utilize the available cooling capacity, either the standard capacity to temporarily increased capacity, by directing the air or liquid coolant to one or more components in need of extra cooling.

Abstract: Systems of an electrical vehicle and the operations thereof are provided. More particularly, a vehicle including a first charging port at a first location on the vehicle and a second charging port at a second location on the vehicle is provided. The first charging port of the vehicle may be different from the second charging port of the vehicle. That is, a standard associated with a receptacle of the first charging port may be different from a standard associated with a receptacle of the second charging port.

Abstract: A phase-change material is used as part of the thermal management system to assist in maintaining a thermal load, such as a battery pack, within a selected temperature range, thereby reducing the consumption of battery power. The phase-change material may be conditioned to an initial state when the vehicle is on-plug and may be used to heat or cool the battery pack directly or indirectly, thereby reducing the use of an electric battery heater. The phase-change material may be used to heat coolant that flows to the thermal load. In another embodiment the phase-change material may be directly within the battery pack in contact with the cells. The phase-change material may be conditioned via the battery circuit heater when the vehicle is on-plug. The phase-change material may also be recharged during vehicle use off-plug using waste heat from the motor circuit thermal load.

Abstract: A vehicle, such as a parallel or series hybrid vehicle, includes both an electric traction motor and a range extending device such as, for example, an internal combustion engine, or a fuel cell. In an embodiment, a thermal management system for the vehicle includes a passenger cabin heating circuit configured to circulate heat exchange fluid through a liquid-to-liquid heat exchanger and a passenger cabin heating heat exchanger. A motor circuit can be configured to circulate heat exchange fluid through the electric traction motor, a transmission control module, and a DC/DC converter. The motor circuit can be selectably connected to the passenger cabin heating circuit by a valve. An engine circuit is configured to circulate heat exchange fluid through the internal combustion engine, a radiator, and the liquid-to-liquid heat exchanger.

Abstract: A thermal management system for an electric vehicle includes a motor circuit for cooling a motor circuit thermal load, a cabin heating circuit for heating a cabin heater and a battery circuit for managing the temperature of a battery circuit thermal load. All of these circuits can fluidically communicate with each other and a single radiator can cool the fluid from all of these circuits.

Abstract: In an aspect, a phase-change material is used as part of the thermal management system to assist in maintaining a thermal load, such as a battery pack, within a selected temperature range, thereby reducing the consumption of battery power. The phase-change material may be conditioned to an initial state when the vehicle is on-plug and may be used to heat or cool the battery pack directly or indirectly, thereby reducing the use of an electric battery heater. The phase-change material may be used to heat coolant that flows to the thermal load. In another embodiment the phase-change material may be directly within the battery pack in contact with the cells. The phase-change material may be conditioned via the battery circuit heater when the vehicle is on-plug. The phase-change material may also be recharged during vehicle use off-plug using waste heat from the motor circuit thermal load.

Abstract: An integrated cooling, sealing and structural battery tray for a vehicle includes a generally planar base member having a support surface and a cooling system formed by the planar base member. A seal is formed between the battery tray and the support structure for the vehicle. The integrated cooling, sealing and structural battery tray may also include a plurality of fins are disposed on the support surface, wherein the fins are adjacent each other, and a plurality of routing apertures extending through the base member and having a plurality of cooling lines disposed therein.

Abstract: A charger and rechargeable energy storage system for a vehicle includes an on-board charging module and a rechargeable energy storage system having a rechargeable energy storage device. The on-board charging module is physically integrated with the rechargeable energy storage system and thermally integrated with the rechargeable energy storage system by a cooling loop, such that waste heat generated by the on-board charging module is reused to warm the rechargeable energy storage device. An optional bypass valve, such as, an electronically controlled bypass valve, can also be connected to the cooling loop to reduce the overall coolant pressure drop when the vehicle is in a drive operational mode.