Abstract: An electric vehicle battery pack with a reinforced cover to better support vehicle cabin loads such as seat submerge loads, seat pitch loads, and the like. The cover has a number of reinforcing members affixed thereto and positioned over cross members of the battery pack frame. Loads imposed by the cabin are thus transferred to the reinforcing members and then to the rigid cross members. In this manner, battery packs of embodiments of the disclosure better support cabin loads applied thereto, improving their strength and better protecting more delicate components within 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: An electric vehicle battery pack with a thermal shield that protects internal components from, for example, battery ventilation, and in particular allows battery pack electrical components to be placed above venting ends of batteries. The thermal shield is positioned above the venting ends of one or more batteries, and various battery pack electrical components may be placed above the thermal shield. Gases and particulate matter from battery venting are thus intercepted and deflected by the thermal shield, instead of damaging battery pack electrical components. In this manner, various battery pack electrical components may be placed above battery venting ends without risk of damage. This allows for a more compact and versatile arrangement of battery pack components.

Abstract: Electric vehicle battery packs with external side enclosures for containing electrical connectors and other components therein. Each enclosure is sized to support various connectors or other components as desired, and may have a number of openings formed to provide interfaces for connecting various electric vehicle systems to the battery pack. The enclosures may be placed at various locations along one or more sides of the battery pack, and connectors may be routed over an upper surface of a battery pack frame or through a gap formed between the pack frame and cover. Enclosures may be made of any material, including plastic for lower weight applications and metal for improved electromagnetic interference shielding.

Abstract: Disclosed embodiments include apparatuses, vehicles, and methods for a displaceable tow hook. In an illustrative embodiment, an apparatus includes a tow hook configured to extend from a surface of a vehicle in a first direction. The tow hook includes a receiving section configured to receive a towing line and a securing section configured to extend away from the receiving section. A positioning mount is configured to secure the tow hook to the surface of the vehicle and to release the tow hook in response to an impinging force on the tow hook in excess of a predetermined threshold. A load-bearing structure is configured to mechanically connect the securing section to a structural component of the vehicle. The tow hook and the load-bearing structure are configured to support a force having a component in the first direction that is at least equal to the towing weight of the vehicle.

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: 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: Systems and methods are provided to vent a battery pack for an electric vehicle. The battery pack comprises a pack housing subdivided by a crossmember. The crossmember defines a multidirectional vent passage configured to allow venting with a first bay and a second bay. A pressure release valve is arranged on the pack housing and configured to release pressure based on the multidirectional vent passage.

Abstract: A vehicle includes a body structure having an occupant compartment, and a frame structure having a chassis. The body structure and the frame structure are fastened together using a plurality of fasteners and an adhesive. To illustrate, the plurality of fasteners may include 20, 50, 70, or more fasteners. The adhesive is arranged at one or more positions along the interface between the body structure to the frame structure. The plurality of fasteners extend beyond the wheel wells, and provide hard mounts between the body structure and frame structure. The adhesive helps to prevent stress concentrations by extending the locations of load transfer between the body structure and the frame structure. Body panels are added before or after the body structure is affixed to the frame structure.

Abstract: Systems and methods are provided for determining a deformation event in a battery pack. The battery pack may comprise a conductive path coupled to a first electrical connector and a second electrical connector. Processing circuitry may be configured to detect a change in an electrical characteristic of the conductive path indicating a transition from a first circuit state of the conductive path to a second circuit state of the conductive path. The processing circuitry may be configured to determine, in response to the detecting, a deformation event in the battery pack.

Abstract: An electric vehicle battery pack with a reinforced cover to better support vehicle cabin loads such as seat submerge loads, seat pitch loads, and the like. The cover has a number of reinforcing members affixed thereto and positioned over cross members of the battery pack frame. Loads imposed by the cabin are thus transferred to the reinforcing members and then to the rigid cross members. In this manner, battery packs of embodiments of the disclosure better support cabin loads applied thereto, improving their strength and better protecting more delicate components within the battery pack.

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: An electric vehicle battery pack with a thermal shield that protects internal components from, for example, battery ventilation, and in particular allows battery pack electrical components to be placed above venting ends of batteries. The thermal shield is positioned above the venting ends of one or more batteries, and various battery pack electrical components may be placed above the thermal shield. Gases and particulate matter from battery venting are thus intercepted and deflected by the thermal shield, instead of damaging battery pack electrical components. In this manner, various battery pack electrical components may be placed above battery venting ends without risk of damage. This allows for a more compact and versatile arrangement of battery pack components.

Abstract: Systems and methods are described herein for venting battery cells in a battery cell pack assembly. An assembly includes a matrix configured to hold battery cells and channel assemblies that each include a venting channel for venting materials (e.g., flammable gas and conductive particulates) from the interior of the matrix to an outlet. Battery cells, particularly lithium ion battery cells, have a chance of entering a thermal runaway condition that causes the production of flammable gas. The assembly is configured such that battery cells are allowed to vent such flammable gas out of the assembly. A ventilation opening and channel in the assembly cause venting materials to be routed through and out of the assembly.

Abstract: Electric vehicle battery packs with external side enclosures for containing electrical connectors and other components therein. Each enclosure is sized to support various connectors or other components as desired, and may have a number of openings formed to provide interfaces for connecting various electric vehicle systems to the battery pack. The enclosures may be placed at various locations along one or more sides of the battery pack, and connectors may be routed over an upper surface of a battery pack frame or through a gap formed between the pack frame and cover. Enclosures may be made of any material, including plastic for lower weight applications and metal for improved electromagnetic interference shielding.

Abstract: Disclosed embodiments include apparatuses, vehicles, and methods for a displaceable tow hook. In an illustrative embodiment, an apparatus includes a tow hook configured to extend from a surface of a vehicle in a first direction. The tow hook includes a receiving section configured to receive a towing line and a securing section configured to extend away from the receiving section. A positioning mount is configured to secure the tow hook to the surface of the vehicle and to release the tow hook in response to an impinging force on the tow hook in excess of a predetermined threshold. A load-bearing structure is configured to mechanically connect the securing section to a structural component of the vehicle. The tow hook and the load-bearing structure are configured to support a force having a component in the first direction that is at least equal to the towing weight of the vehicle.

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: Systems and methods are described herein for venting battery cells in a battery cell pack assembly. An assembly includes a matrix configured to hold battery cells and channel assemblies that each include a venting channel for venting materials (e.g., flammable gas and conductive particulates) from the interior of the matrix to an outlet. Battery cells, particularly lithium ion battery cells, have a chance of entering a thermal runaway condition that causes the production of flammable gas. The assembly is configured such that battery cells are allowed to vent such flammable gas out of the assembly. A ventilation opening and channel in the assembly cause venting materials to be routed through and out of the assembly.

Abstract: A battery enclosure is provided having unswitched positive and negative terminals that are physically separated. The unswitched positive and negative terminals may be connected to circuit protection components, such as contactors and fuses. The contactors are set to an opened or closed state via a contactor control module. The battery enclosure includes external terminals that electrically couple the battery and circuit protection devices to external components, such as charging ports and electrical loads.