Abstract: An electric vehicle battery pack cover with a fiber reinforced multiple-ply composite body whose bottom surface is coated with a high-hardness, high-melting point, and fire- and abrasion-resistant coating. The coating can be any one or more materials that provide sufficient fire and abrasion resistance to allow the battery pack to contain a battery fire. As examples, the coating can be a nickel layer, a steel layer, a high temperature mineral layer such as a mica layer, or any combination of these materials. The composite body can be any composite body that is both compatible with the fire- and abrasion-resistant coating and provides sufficient strength to act as a battery cover. As examples, the composite body can be made of one or more glass fiber plies, carbon fiber plies, aramid fiber plies, or any combination of any number of these plies, with a crosslinked polymer or other matrix.

Abstract: A battery system includes a battery frame, a battery module, and a polymeric seat. The battery frame includes a horizontal bottom plate and a plurality of members that extend in a vertical direction from the bottom plate. The battery module includes at least one battery cell enclosed inside body of the battery module. The battery module also includes an attachment surface fixedly attached to the body and one or more supports that extend downward from to the body. The attachment surface is fixedly attached to one or more of plurality of members to generate a force on the one or more supports in a direction of the bottom plate. The polymeric seat is fixedly attached to either the one or more supports or the battery frame and removably contacts the other of the one or more supports or the battery frame. The polymeric seat is compressed in response to the force.

Abstract: Efficiency of a battery module is achieved using an actively cooled high power electrical interface. The battery module comprises a plurality of battery cells, at least one busbar coupled to the battery cells, a connector electrically coupled to the at least one busbar, and at least one cooling component that is thermally coupled to the first connector. The battery cells may be arranged in two layers, each layer containing a plurality of battery cells connected by a busbar. The connector comprises a contact through which the battery module may be coupled to an external circuit. The at least one cooling component provided cooling for the battery cells and the connectors and may be placed on the surface of the battery module or between layers of battery cells.

Abstract: An electrically conductive member can include a first opening and a second opening. The first opening of the electrically conductive member can engage a first member of a cell carrier to at least partially align the electrically conductive member with the cell carrier. The second opening of the electrically conductive member can engage with a second member of the cell carrier for coupling the electrically conductive member with the cell carrier.

Abstract: A flex circuit and a battery module including the flex circuit are provided. The flex circuit includes a first plurality of conductive traces and a second plurality of conductive traces. Each of the first plurality of conductive traces includes a first terminal configured to be electrically coupled to a first location of a respective one of a plurality of busbars that electrically connect battery cells of the battery module, and a second terminal configured to be electrically coupled to processing circuitry. Each of the second plurality of conductive traces includes a first terminal configured to be electrically coupled to a second location of a respective one of the plurality of busbars, and a second terminal configured to be electrically coupled to the processing circuitry. The processing circuitry is configured to measure a voltage level of each of the plurality of busbars using the first and second plurality of conductive traces.

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.

Abstract: Electric vehicle battery pack whose cover is more fully sealed against leakage. The cover is connected to the battery pack frame by fasteners that are affixed to the surface of the cover rather than being fastened through holes therein, or that are sealed to prevent leakage. The cover thus has no, fewer, or sealed holes formed within, and thus has fewer pathways for leakage or infiltration of moisture into the battery pack.

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: Electric vehicle battery pack whose cover is more fully sealed against leakage. The cover is connected to the battery pack frame by fasteners that are affixed to the surface of the cover rather than being fastened through holes therein, or that are sealed to prevent leakage. The cover thus has no, fewer, or sealed holes formed within, and thus has fewer pathways for leakage or infiltration of moisture into the battery pack.

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 fluid mating system includes a fitting connector, a mating connector and a planar slip system. The fitting connector includes an exterior mating surface and a first interior fluid passage that permits fluid flow along a first direction. The mating connector includes an interior surface that includes a tapered lead-in portion, an interior mating surface, and a second interior fluid passage. The second interior fluid passage permits fluid flow in the first direction. The first interior fluid passage and the second interior fluid passage include a single fluid path when the interior mating surface is engaged with the exterior mating surface. The planar slip system restricts movement of the mating connector in the first direction and allows at least partial free movement of the mating connector within a plane that is perpendicular to the first direction.

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 system includes battery cells arranged and adhered to a carrier. One or more side walls are bonded with adhesive to the battery cells to provide support, and a current collector assembly is also adhered on one axial side of the battery cells. One or more dividers may be included to maintain electrically isolation between the parallel connected battery cell groups. The other axial side of the battery cells is adhered to a cooling plate. A similar structure is bonded with adhesive to the other side of the cooling plate to form a compact battery system. Shear walls, busbars, terminal busbars, and an isolation bracket with a mounted Electronic Control Unit are bonded with adhesive to the assembly to form the battery system. Each adhesive, or type of adhesive, may exhibit specified criteria and requirements such as strength, thermal conductivity, electronic conductivity, curing requirements, or a combination thereof.

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 battery module and a method of manufacturing a battery module are provided. The battery module includes a plurality of current collectors configured to electrically connect battery cells of the battery module together, and a flex circuit. The battery module is configured to have a number of electrical connections between the plurality of current collectors and the flex circuit. The flex circuit comprises a number of connection terminals, each capable of being electrically coupled to a current collector of the plurality of current collectors. The number of connection terminals is greater than the number of electrical connections. The electrical connections are made between the plurality of current collectors and a subset of the connection terminals of the flex circuit.

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: 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.