Dimaag-ai, Inc.

Wrightspeed, Inc.

Arcbyt, Inc.

Cisco Technology, Inc.

Tesla Motors, Inc.

Phoenix Boring, Inc.

Ian Wright

David Kieke

Sean McLean

Max Chapman

Ryan Cash

Shivani Torres

Matthew James Wright

David Beard

Arielle Dobrowolski

Brandon Stitt

Eugene Michael Berdichevsky

Martin F Eberhard

David Frederick Lyons

Jeffrey Brian Straubel

Fuk Ho Pius Ng

Thomas E Colson

Robert R Ferber

George Fellingham

Brian Graf

Described herein are DC-DC converters with a ratio of the power output to volume of at least 2 kW per liter or even at least 4 kW per liter. Such DC-DC converters can operate at power levels of at least 150 kW or even at least 200 kW. A DC-DC converter comprises an enclosure and a front plate sealed against the enclosure using a set of fasteners. The DC-DC converter also comprises a converter unit comprising a switching sub-module, a diode sub-module, and an inductor as well as an additional converter unit comprising an additional switching sub-module, an additional diode sub-module, and an additional inductor. The switching sub-module and the additional switching sub-module or, more generally, the converter unit and the additional converter unit are configured to operate out of phase. The inductors are immersed cooled, the switching sub-modules are conductively cooled, while the diode sub-modules are convectively cooled.

Compact high-power DC-to-DC converters with out-of-phase converter units and multiple cooling types

Disclosed are systems and methods to bore or tunnel through various geologies in an autonomous or substantially autonomous manner including one or more non-contact boring elements that direct energy at the bore face to remove material from the bore face through the fracture, spallation, and removal of the material. Systems can automatically execute methods to control a set of boring parameters that affect the flux of energy directed at the bore face. Systems can further automatically execute the methods to: monitor, direct, maintain, and/or adjust a set of boring controls, including for example a standoff distance between the system and the bore face, a temperature of exhaust gases directed at the bore face, a removal rate of material from the bore face, and/or a thermal or topological characterization of the bore face during boring operations.

Systems and methods for non-contact boring

Low-noise electric lawnmowers comprise curved cutting blades. In some examples, a lawnmower comprises a driving unit and a mowing unit with a mowing-unit deck. The mowing-unit deck comprises a set of blade units (e.g., 3 units) and a discharge conduit. Each blade unit comprises a blade enclosure and a cutting blade with a cutting edge having a curved shape. For example, the cutting edge, at a point furthest away from the blade center axis, may form an approach angle of greater than 90° but be less than 90° closer to the blade center. This curving aspect allows operating the blade at lower rotating speeds (e.g., less than 3,000 RPM), which reduces the turbulence and noise. In some examples, the blade enclosure forms an enclosure tunnel such that the tunnel's cross-sectional area increases from the tunnel's inlet to the outlet.

Low-noise electric lawnmowers with curved cutting blades

Described herein are battery modules comprising immersion-cooled prismatic battery cells and methods of fabricating thereof. A battery module comprises prismatic battery cells that are stacked along the primary module axis. The module also comprises top, bottom, and side covers and two end plates, collectively enclosing these battery cells. Each cover forms two fluid channels, both fluidically open to the prismatic battery cells. Furthermore, the module comprises bus bars that interconnect the cell terminals and protrude into the fluid channels formed by the top cover. One end plate comprises two fluid ports for connecting to a thermal management system. Each port is fluidically coupled to one fluid channel, formed by the top cover, and one fluid channel, formed by the bottom cover. The other end plate fluidically couples the two fluid channels, formed by the top cover, and, separately, the two fluid channels, formed by the bottom cover.

Battery modules comprising immersion-cooled prismatic battery cells and methods of fabricating thereof

Described herein are electric vehicles comprising power distribution systems and methods of operating thereof. Specifically, a power distribution system is mechanically coupled to an electric motor, a road wheel, and an auxiliary unit. This system is configured to switch among multiple operating modes and selectively transfer mechanical power among the electric motor, wheel, and auxiliary unit. For example, the power distribution system is configured to transfer mechanical power between the electric motor and the road wheel, but not the auxiliary unit, when switched to a wheel operating mode. The power distribution system is configured to transfer mechanical power between the electric motor and the auxiliary unit, but not the road wheel, when switched to an auxiliary operating mode. The power distribution system is configured to transfer mechanical power between the electric motor, the auxiliary unit, and the road wheel when the system is switched to a combined operating mode.

Electrical vehicles comprising power distribution systems and methods of operating thereof

Described herein are immersion-cooled axial flux electric motors and methods of operating thereof. An immersion-cooled axial flux electric motor comprises a rotor and an immersion-cooled stator. The rotor comprises a set of magnets and a magnet support plate extending perpendicular to the motor axis. The set of magnets is attached to the magnet support plate and distributed about on the motor axis. The immersion-cooled stator comprises a cooling-fluid inlet, a cooling-fluid outlet, a set of stator windings, and a stator-sealed space. The set of stator windings is positioned within the stator-sealed space proximate to the set of magnets such that during the operation of the motor magnetic flux between the set of stator windings and the set of magnets is aligned substantially parallel to the axis of rotation of the rotor. The cooling-fluid inlet and the cooling-fluid outlet are fluidically coupled to the stator-sealed space.

Immersion-cooled axial flux electric motors and methods of operating thereof

A foldable non-highway electric vehicle (EV) for recreational use. The non-highway EV may include a chassis and a foldable battery module coupled to the chassis. The foldable battery module may fold to a position to allow portable transport of the non-highway EV. Suspension may control movement of the wheels relative to the chassis. The suspension may also be set in a plurality of different configurations, including a configuration where the suspension is set in a transport position. With the battery folded and the suspension set in the transport position, the footprint of the non-highway EV may be significantly reduced, to allow for convenient transportation of the non-highway EV.

Foldable off-road electric vehicle

Described herein are swappable battery modules comprising immersion-thermally controlled prismatic battery cells and methods of operating thereof. A method comprises positioning a swappable battery module on an external charger comprising charger fluidic ports and sliding the swappable battery module to the charger fluidic ports until these charger's ports are fluidically coupled with the module's fluidic ports. Specifically, the external charger comprises an enclosure and a module support rail slidably coupling the swappable battery module and the enclosure. The module support rail comprises a rail base, a first slider, a second slider, and a lever-based unit, interconnecting the rail base and both sliders. The rail base is fixed to the enclosure, while the second slider is detachably coupled to the module. The two sliders move at different speeds or at the same speed relative to the charger base depending on proximity of the first end plate to the charger base.

Swappable battery modules comprising immersion-thermally controlled prismatic battery cells and methods of fabricating thereof

Described herein is a gearbox for an electric vehicle drivetrain unit comprising a gearbox enclosure, a support rod, a first piston, a second piston, and various hydraulic fluid passages. The support rod extends into the gearbox enclosure and at least partially protrudes/extends into the first and second pistons. The first piston, second piston, and support rod are fluidically connected with the hydraulic fluid passages such that when the gearbox is in a neutral gear, pressurized hydraulic fluid forces the first piston and the second piston against the support rod. When the gearbox is in a first gear, pressurized hydraulic fluid forces the support rod against the gearbox enclosure either directly or through the first piston. When the gearbox is in a second gear, pressurized hydraulic fluid forces the support rod against the gearbox enclosure directly or through the second piston. Also described are electric vehicles and shifting methods.

Gearboxes for electric vehicle drivetrains and methods of shifting thereof

Electric lawnmowers comprise drive units and mowing units disengageably coupled to the drive units. For example, a drive unit can be disengageably coupled to any one of multiple mowing units (e.g., rotating mowing units, reel mowing units) collecting forming a mowing system. For example, each of the drive and mowing units may be equipped with corresponding mechanical-engagement structures that are configured to be disengageably coupled. Each mowing unit is equipped with its electric motor (e.g., for rotating the cutting blades or the reel of that unit). The electric motor may comprise an electric connector, which is disengageably coupled to the drive unit's electrical wiring. In some examples, each mowing unit can also form a liquid disengageable coupling for circulating a thermal liquid between the drive unit and mowing unit, e.g., for cooling various components of the drive unit.

Electric lawnmowers with interchangeable mowing units and methods of operating thereof

Described herein are DC-DC converters with electronic module cooling units used for air-convection cooling of some components of power electronic modules and conductive cooling of other components, e.g., switching sub-modules. A cooling unit may have a heat exchanger and a cooling plate, thermally coupled to one or more heat exchangers and one or more switching sub-modules. For example, the cooling plate can be positioned between and thermally coupled to heat exchangers. One fan can direct air through one heat exchanger and to one power electronic module as a part of convection cooling. An additional fan can direct air through the second heat exchanger and to the second power electronic module. The cooling plate can be also positioned between and thermally coupled to switching sub-modules of these power electronic modules thereby enabling conductive cooling. The plate-cooling liquid is pumped through the cooling plate.

Liquid and air cooling of DC-to-DC converters and methods of operating thereof

Electric lawnmowers comprise mowing-unit decks with fluid passages used for cooling batteries, power electronics units, and/or drive motors. Specifically, a lawnmower comprises a drive unit (with a battery, power electronics, and one or more drive motors) and a mowing unit (with a mowing-unit deck). The deck's fluid passage is fluidically coupled to the drive unit (e.g., the motor and power electronics). The thermal liquid is heated by the drive unit's components and cooled as the liquid passes through the deck's fluid passage. The mowing unit may be equipped with a pump (for circulating this liquid), which can be powered by an electric motor on the mowing unit. The same motor may be used for rotating the cutting blades. The drive unit may have an additional cooling circuit providing immersion cooling to the batteries.

Electric lawnmowers with cooling features integrated into mowing-unit enclosures and methods of operating thereof

Described herein are battery modules comprising integrated module converters, electric-vehicle battery systems comprising such modules, and methods of operating thereof. An electric-vehicle battery system comprises a high-voltage battery pack and high-voltage contactors that controllably isolate the pack's high-voltage area from other areas in the vehicle. The pack comprises multiple battery modules with battery cells and a primary module converter constantly connected to these cells. Each module has a lower voltage than the entire pack. The power output from the primary module converters is used to operate a battery controller and to close/activate the contactors in response to the switch position (e.g., an ignition switch). The primary module converters can be either constantly activated or controllably activated in response to the switch moving into an activated position. For example, a secondary module converter, with a lower power rating, can be used for this primary module converter activation.

Growing community of inventors

Woodside, CA, United States of America

Ian Wright