Abstract: A power source is provided for integration with a thermal regulation subsystem. The power source includes a battery pack and a heat exchanger that is used to transfer heat between a first heat transfer fluid associated with the thermal regulation subsystem, and a second heat transfer fluid associated with the battery pack. A thermal management unit actuates a second heat transfer fluid valve to control flow of the second heat transfer fluid through flow loops that include and exclude the heat exchanger based on a temperature of the battery pack. The thermal management unit may activate electrically-powered heat transfer elements of the heat exchanger based on the temperature of the battery pack.

Abstract: A power control system for a vehicle includes a charge port and a contactor connected to the charge port and including a first plurality of switches. An energy storage system includes a second plurality of switches and one or more battery packs. A bi-directional DC-DC converter is connected between the energy storage system and a plurality of vehicle loads. A controller is configured to control states of the first and second plurality of switches to configure in a plurality of modes including a range improvement mode, a first charging mode to perform charging at a first voltage level, a second charging mode to perform charging at a second voltage level, a battery preconditioning mode; and an accessory load support mode.

Abstract: A power control system for a battery system of a vehicle includes one or more supplemental protection devices that are connected to at least one of a first contactor, a second contactor, one of N fuses, and one of N vehicle loads. A battery management module is configured to measure and store a plurality of state of health parameters for the battery system and to selectively operate the one or more supplemental protection devices in a coverage gap between first and second coverage areas handled by the first contactor and the second contactor and the N fuses based on a calibration function and/or calibration parameters. A telematics system selectively sends the plurality of state of health parameters for the battery system to a remote server and to receive at least one of a new calibration function and new calibration parameters for the vehicle from the remote server.

Abstract: An electric vehicle includes an electrical system and performs a method of charging the electric vehicle. The electrical system includes a first battery subpack, a second battery subpack, wherein the first battery subpack, the second battery subpack, and an electrical load of the electric vehicle are connected in parallel, and a processor. The processor is configured to control a first connection between the first battery subpack and a first charge port and a second connection between the second battery subpack and a second charge port to charge each of the first battery subpack and the second battery subpack while providing power to the electrical load.

Abstract: Aspects of the disclosure include a pre-formed battery cell thermal barrier for a battery module. An exemplary battery module can include a plurality of conductively coupled electrochemical cells and a pre-formed thermal barrier. The battery module can further include a cell holder configured to receive the plurality of conductively coupled electrochemical cells and the pre-formed thermal barrier. The pre-formed thermal barrier includes a cured potting material insertable into a cell-to-cell space in the battery module.

Abstract: A method for charging an electric vehicle is provided. Aspects include configuring a switchable battery of the electric vehicle in a fast-charging configuration by connecting a first battery pack of the switchable battery to a first charging source and a second battery pack of the switchable battery to a second charging source and obtaining one or more characteristics of the first battery pack and the second battery pack. Aspects also include identifying the first battery pack as a master pack and the second battery pack as a follower pack based on a determination that the first battery pack has a lower voltage level than the second battery pack. Aspects further include adjusting a duty cycle of a switchable active load connected in parallel to the follower pack based on the one or more characteristics of the first battery pack and the second battery pack.

Abstract: A modular cell holder assembly includes a first cell holder member including a first cell receptacle and a second cell holder member including a second cell receptacle. The second cell holder member is connected with the first cell holder member forming a modular cell holder with the first cell receptacle and the second cell receptacle combining to form a cell receiving zone. A plurality of current connectors is provided on an outer surface of one of the first cell holder member and the second cell holder member. The plurality of current connectors is configured to establish a selected electrical configuration of energy storage cells in the cell receiving zone.

Abstract: An electric vehicle charging system including a switchable battery having at least two battery packs that are selectively arranged in one of a fast-charging configuration and a drive configuration. The fast-charging configuration includes connecting each of the at least two battery packs to separate charging sources and the drive configuration includes connecting each of the at least two battery packs in parallel. The charging system including a plurality of sensors configured to measure one or more characteristics of the at least two battery packs and a controller configured to calculate an adjustment to a charging current of one of the at least two battery packs based on the one or more characteristics and transmit the adjustment to a charging source associated with the one of the at least two battery packs.

Abstract: An electric vehicle includes an electrical system and performs a method of charging the electric vehicle. The electrical system includes a first battery subpack, a second battery subpack, wherein the first battery subpack, the second battery subpack, and an electrical load of the electric vehicle are connected in parallel, and a processor. The processor is configured to control a first connection between the first battery subpack and a first charge port and a second connection between the second battery subpack and a second charge port to charge each of the first battery subpack and the second battery subpack while providing power to the electrical load.

Abstract: An electric vehicle, system and method of charging the electric vehicle. In another exemplary embodiment, a system for charging an electric vehicle is disclosed. The system includes a first battery subpack, a second battery subpack, and a processor. The processor is configured to determine a selected battery subpack from the first battery subpack and the second battery subpack for charging based on a comparison of a first state of charge of the first battery subpack a second state of charge of the second battery subpack and connect the selected battery subpack to a corresponding one of a first charge port and a second charge port.

Abstract: Examples described herein provide a method that includes receiving, at a vehicle comprising a first battery pack and a second battery pack, at least one of a first electric charge from a first charging station via a first charging port or a second electric charge from a second charging station via a second charging port. The method further includes determining, by a controller of the vehicle, a charging mode of the vehicle. The charging mode is selected from a group consisting of a dynamic balancing during independent multi-port charging mode, a dynamic balancing during independent port charging mode, or a dynamic balancing during parallel charging mode. The method further includes configuring, by the controller of the vehicle, a plurality of switches of a rechargeable energy storage system of the vehicle based at least in part on the determined charging mode.

Abstract: A system in a vehicle includes two or more smart battery packs to power drive units of the vehicle to move the vehicle. Each of the two or more smart battery packs includes a battery pack, and a battery management system (BMS) to monitor a state of charge of the battery pack. An energy distribution unit facilitates charge transfer among the two or more smart battery packs.

Abstract: A system includes a battery system including a plurality of batteries and configured to be selectively coupled to and charged by a renewable energy source and selectively coupled to and charged by a power grid. The system further includes a DC bus shared by a plurality of loads and an energy management system connected between the battery system and the plurality of loads. The energy management system is configured to selectively connect individual ones of the plurality of batteries to at least one of the plurality of loads via the DC bus, selectively connect the battery system to the power grid and disconnect the battery system from the power grid, and selectively connect at least one of the plurality of loads directly to the power grid.

Abstract: A protection system for a battery system includes a battery control module configured to selectively open at least one contactor to isolate the battery system from a load in response to a sensed current being greater than a first threshold and within a first current range, at least one fuse connected between first and second terminals of the battery system and configured to open to isolate the battery system from the load in response to the sensed current being greater than a second threshold and within a second current range that is greater than and offset from the first current range, and an auxiliary protection module configured to selectively form a short circuit between first and second terminals in response to the sensed current being greater than the first threshold, less than the second threshold, and within a coverage gap region between the first and second current ranges.

Abstract: A battery module includes: positive and negative terminals disposed on an exterior of a housing of the battery module; groups of two or more cylindrical battery cells, each of the battery cells of each group having positive and negative terminals; and electrically conductive busbars that electrically connect the groups, that electrically connect positive terminals of the battery cells of a first one of the groups with the positive terminal of the battery module, and that electrically connect negative terminals of the battery cells of a second one of the groups with the negative terminal of the battery module; and a cooling plate including: first and second second planar plates; and a coolant channel plate that is sandwiched between the first and second planar plates that includes: an inlet; an outlet; and a coolant channel that extends in at least two different directions.

Abstract: A battery module includes: positive and negative terminals disposed on an exterior of a housing of the battery module; groups of cylindrical battery cells, each of the battery cells of each group having a positive and negative terminals, and a vent; and electrically conductive busbars that electrically connect the groups, that electrically connect positive terminals of the battery cells of a first one of the groups with the positive terminal of the battery module, and that electrically connect negative terminals of the battery cells of a second one of the groups with the negative terminal of the battery module; and a thermal runaway protection blanket including: a first surface; a second surface opposite the first surface; and recessed portions that are recessed relative to the second surface and that extend toward the first surface, where the vents of at least a portion of the battery cells face the recessed portions.

Abstract: A battery module includes: a positive terminal disposed on an exterior of a housing of the battery module; a negative terminal disposed on the exterior of the housing of the battery module; groups of two or more cylindrical battery cells electrically connected in parallel; and electrically conductive bus bars that electrically connect the groups in series, that electrically connect positive terminals of the cylindrical battery cells of a first one of the groups with the positive terminal of the battery module, and that electrically connect negative terminals of the cylindrical battery cells of a second one of the groups with the negative terminal of the battery module.

Abstract: A power control system for a battery system of a vehicle includes a first contactor, a second contactor, N fuses and N vehicle loads. An active sacrificial protection device includes a third contactor and a first fuse. The active sacrificial protection device is connected to a positive or negative terminal of the battery system. A current sensor is configured to sense a measured load current flowing through one of the first contactor and the second contactor. A battery management module is configured to selectively close the third contactor to reduce current flowing through one of the first contactor or the second contactor and selectively open the one of the first contactor or the second contactor after closing the third contactor.

Abstract: A system in a vehicle includes two or more smart battery packs to power drive units of the vehicle to move the vehicle. Each of the two or more smart battery packs includes a battery pack, and a battery management system (BMS) to monitor a state of charge of the battery pack. An energy distribution unit facilitates charge transfer among the two or more smart battery packs.

Abstract: A system in an electric vertical take-off and landing (eVTOL) aircraft includes two or more subsystems. Each subsystem includes an energy storage systems (ESS). Each ESS is coupled to one or more motors that actuate one or more rotors of the eVTOL aircraft and includes one or more energy sub-packs and one or more power sub-packs. The one or more power sub-packs supply more power than the one or more energy sub-packs and the one or more energy sub-packs supply consistent power for a longer duration than the one or more power sub-packs. The system also includes one or more inter-subsystem switches to electrically isolate or connect adjacent ones of the two or more subsystems.