Patent application number | Description | Published |
20080311468 | Optimized cooling tube geometry for intimate thermal contact with cells - A battery pack thermal management system for use in an electrical vehicle is disclosed. The battery pack thermal management system includes a manifold and a plurality of cells arranged in a predetermined pattern within the battery pack. The system also includes a cooling tube having a scallop like outer surface in thermal contact with the cells and in fluid communication with the manifold. The thermal management system will cool the battery pack to a predetermined temperature to increase the longevity of the battery pack within the electric vehicle. | 12-18-2008 |
20090140698 | Multi-mode charging system for an electric vehicle - A method and apparatus that allows the end user to optimize the performance of an all-electric or hybrid vehicle and its charging system for a desired mode of operation is provided. The system of the invention includes multiple charging/operational modes from which the user may select. Each charging/operational mode controls the cut-off voltage used during charging and the maintenance temperature of the battery pack. | 06-04-2009 |
20090140700 | Multi-mode charging system for an electric vehicle - A method and apparatus that allows the end user to optimize the performance of an all-electric or hybrid vehicle and its charging system for a desired mode of operation is provided. The system of the invention includes multiple charging/operational modes from which the user may select. Each charging/operational mode controls the cut-off voltage used during charging and the maintenance temperature of the battery pack. | 06-04-2009 |
20090143929 | Multi-mode charging system for an electric vehicle - A method and apparatus that allows the end user to optimize the performance of an all-electric or hybrid vehicle and its charging system for a desired mode of operation is provided. The system of the invention includes multiple charging/operational modes from which the user may select. Each charging/operational mode controls the cut-off voltage used during charging and the maintenance temperature of the battery pack. | 06-04-2009 |
20090167254 | Multi-mode charging system for an electric vehicle - A method and apparatus that allows the end user to optimize the performance of an all-electric or hybrid vehicle and its charging system for a desired mode of operation is provided. The system of the invention includes multiple charging/operational modes from which the user may select. Each charging/operational mode controls the cut-off voltage used during charging and the maintenance temperature of the battery pack. | 07-02-2009 |
20090243538 | SYSTEM AND METHOD FOR BATTERY PREHEATING - Some embodiments include a system, that includes an electric motor coupled to propel an electrical vehicle, a battery coupled to power the motor, a preheating system coupled to preheat the battery, a battery temperature comparator to compare a temperature of the battery to a target preheated temperature and to provide a battery below temperature signal when the battery temperature is below a specified temperature, a control circuit to determine the time remaining prior to a scheduled drive start time and to provide a preheating enable signal during a target time interval prior to the scheduled drive start time and a further control circuit to operate the preheating system in response to the battery below temperature signal and the preheating enable signal. | 10-01-2009 |
20100075213 | Cell thermal runaway propagation resistant battery pack - A means for inhibiting the propagation of thermal runaway within a plurality of batteries is provided, wherein the means is comprised of a layer of intumescent material covering the interior surfaces of the battery pack. | 03-25-2010 |
20100075221 | Cell thermal runaway propagation resistance using an internal layer of intumescent material - A means for inhibiting the propagation of thermal runaway within a plurality of batteries is provided, wherein the means is comprised of at least one layer of intumescent material interposed between the interior surface of the casing of a battery and the corresponding electrode assembly. | 03-25-2010 |
20100104935 | HEAT DISSIPATION FOR LARGE BATTERY PACKS - One embodiment includes an electrical cell that includes a flat housing, at least one electrode and an electrically and heat conductive tab coupled to the electrode and extending through the housing for electrically and thermally coupling to a collector panel, the tab being capable of conducting both current and a substantial amount of heat out of the housing to a temperature control system. The cells may be stacked to form a battery having a temperature panel interfaced to the temperature control system by a thermal interface. The battery may propel an electrically-powered vehicle or the like. | 04-29-2010 |
20100104938 | Liquid cooling manifold with multi-function thermal interface - A liquid cooling manifold assembly for use in the thermal management system of a battery pack is provided. The liquid cooling manifold assembly includes a coolant channel portion through which the coolant channels run, and a dual layer thermal interface interposed between the coolant channel portion and the cells of the battery pack. The outer material layer of the dual layer thermal interface is comprised of an electrically non-conductive, high dielectric material that is preferably tear resistant, deformable and has a high tensile strength and a relatively low surface friction. The inner material layer of the dual layer thermal interface is comprised of a highly compressible material. | 04-29-2010 |
20100135355 | Battery thermal event detection system using an optical fiber - A method and apparatus is provided for determining when a battery, or one or more batteries within a battery pack, undergoes an undesired thermal event such as thermal runaway. The system uses an optical fiber mounted in close proximity to, or in contact with, an external surface of the battery or batteries to be monitored. A source of light is optically coupled to the input facet of the optical fiber and a detector optically coupled to the output facet of the optical fiber. Battery health is determined by monitoring the light transmitted through the optical fiber. | 06-03-2010 |
20100136384 | Battery thermal event detection system using an electrical conductor with a thermally interruptible insulator - A method and apparatus is provided for determining when a battery, or one or more batteries within a battery pack, undergoes an undesired thermal event such as thermal runaway. The system uses an insulated conductive member mounted in close proximity to, or in contact with, an external surface of the battery or batteries to be monitored. A voltage measuring system is coupled to the conductive core of the insulated conductive member, the voltage measuring system outputting a first signal when the temperature corresponding to the battery or batteries is within a prescribed temperature range and a second signal when the temperature exceeds a predetermined temperature that falls outside of the prescribed temperature range. | 06-03-2010 |
20100136385 | Method and apparatus for maintaining cell wall integrity during thermal runaway using an outer layer of intumescent material - A method and apparatus is provided in which a layer of an intumescent material surrounds the casing of a battery, the layer helping to prevent the formation of perforations in the battery casing during a thermal runaway event and, if a perforation is formed, inhibiting the flow of hot, pressurized gas from within the battery. A sleeve, surrounding the cell, may be used to contain the intumescent material during the thermal event. | 06-03-2010 |
20100136387 | Cell cap assembly with recessed terminal and enlarged insulating gasket - A simplified cell design is provided for a battery utilizing the 18650 form-factor, the simplified cell design reducing manufacturing cost, battery weight and the risk of shorting between the battery case and the battery terminal. In the cap assembly of the disclosed battery, the safety vent element, which is recessed relative to the top of the cell case, also serves as the battery terminal. Additionally, the insulating gasket positioned between the cell case and the cap assembly is designed to cover a large portion of the outer surface of the safety vent/battery terminal. | 06-03-2010 |
20100136391 | Active Thermal Runaway Mitigation System for Use Within a Battery Pack - An active thermal runaway mitigation system is provided that mitigates the effects of a single cell undergoing thermal runaway, thereby preventing the propagation of the thermal runaway event to neighboring cells within the battery pack. The provided system includes at least one, fluid-containing conduit in proximity to the cells within the battery pack. The conduit includes a plurality of breach points in proximity to the subset of cells, where each breach point is configured to form a breach at a preset temperature that is lower than the melting temperature of the conduit. Once a breach is formed, the fluid contained within the conduit is discharged through the breach. | 06-03-2010 |
20100136396 | Cell Separator for Minimizing Thermal Runaway Propagation within a Battery Pack - A spacer assembly for use with a cell mounting bracket in a battery pack is provided. The spacer assembly, comprised of one or more spacers, maintains the positions of the batteries within the battery pack during a thermal event and after the cell mounting bracket loses structural integrity due to the increased temperature associated with the thermal event. By keeping the battery undergoing thermal runaway in its predetermined location within the battery pack, the minimum spacing between cells is maintained, thereby helping to minimize the thermal effects on adjacent cells while ensuring that the cooling system, if employed, is not compromised. As a result, the risk of thermal runaway propagation is reduced. | 06-03-2010 |
20100136402 | Sealed battery enclosure - A sealed battery enclosure to extend the life of the batteries contained therein is provided, the sealed battery enclosure significantly reducing contamination from water or other liquids and gases. | 06-03-2010 |
20100136404 | Thermal barrier structure for containing thermal runaway propagation within a battery pack - A battery pack is provided that includes one or more thermal barrier elements, the thermal barrier elements dividing the cells within the battery pack into groups of cells. The thermal barrier elements that separate the cells into groups prevent a thermal runaway event initiated in one group of cells from propagating to the cells within a neighboring group of cells. | 06-03-2010 |
20100136407 | Battery cell with a partial dielectric barrier for improved battery pack mechanical and thermal performance - The adverse effects of the dielectric material covering the lateral outer surface of a conventional battery are eliminated by replacing it with a dielectric barrier that covers less than 20 percent of the lateral outer surface of the cell case; more preferably less than 15 percent of the lateral outer surface of the cell case; still more preferably less than 10 percent of the lateral outer surface of the cell case; and yet still more preferably less than 5 percent of the lateral outer surface of the cell case. The dielectric barrier may be shrunk-fit, bonded, friction-fit or otherwise held in place. An electrically insulating disk may be interposed between the dielectric barrier and the end edge portion of the cell case. | 06-03-2010 |
20100136413 | Method and apparatus for the external application of battery pack encapsulant - A method and apparatus for simplifying battery pack encapsulation is provided. The battery pack includes a pair of complementary housing members with each housing member including a plurality of cell contraints into which the ends of corresponding battery cells are inserted during assembly. One or both housing members also include at least one, and preferably a plurality, of raised encapsulant injection ports. The raised encapsulant injection ports are designed to extend above the surface of the respective housing members and beyond the injected encapsulation material, thus ensuring that the ports remain open after encapsulation material injection. | 06-03-2010 |
20100136421 | Cell cap assembly with recessed terminal and enlarged insulating gasket - A simplified cell design is provided for a battery utilizing the 18650 form-factor in which the CID and PTC elements are eliminated, thereby reducing manufacturing cost and battery weight. To reduce the risk of shorting between the battery case and the battery terminal, the battery terminal is recessed relative to the top of the cell case and the insulating gasket positioned between the cell case and the cap assembly is designed to cover a large portion of the outer surface of the terminal element. | 06-03-2010 |
20100136424 | Multi-wall battery for maintaining cell wall integrity during thermal runaway - A battery is provided in which a thermal insulator or other material is interposed between the electrode assembly and the inner surface of the cell casing, the additional layer(s) inhibiting the formation of wall perforations in the battery casing during a thermal runaway event. | 06-03-2010 |
20100151308 | INCREASED RESISTANCE TO THERMAL RUNAWAY THROUGH DIFFERENTIAL HEAT TRANSFER - One embodiment includes a housing, a first battery cell having a first cell thermal capacitance, the first cell fixedly disposed in the housing, a second battery cell having a second cell thermal capacitance, the second cell fixedly disposed in the housing a minimum air gap away from the first cell, the minimum air gap having an air gap thermal resistance and a heat conductor disposed adjacent each of the cells, with the heat conductor having a heat conductor heat capacitance. A combination of the first cell thermal capacitance, the second cell thermal capacitance, the heat conductor thermal capacitance and the air gap is sufficient to restrict heat flow from the first cell to the second cell during a thermal runaway event of the first cell, the heat flow restricted such that the second cell temperature remains less than a temperature sufficient to cause thermal runaway in the second cell. | 06-17-2010 |
20100211242 | OPERATION OF A RANGE EXTENDED ELECTRIC VEHICLE - One embodiment includes a method that includes monitoring a battery state of charge circuit that is coupled to a vehicle battery, calculating an averaged value of the state of charge over a time period, charging the vehicle battery by powering a generator with a fuel burning engine that powered on and powered off according to one of a first operational mode and a second operational mode, wherein in the first operational mode the engine is powered on when the battery state of charge drops below a first state of charge and continues until the averaged value of the state of charge increases to a first preprogrammed value. | 08-19-2010 |
20100212338 | Battery pack temperature optimization control system - A method and apparatus for limiting the adverse effects of temperature on the electrical energy storage system (ESS) of an electric vehicle after the vehicle has been turned off are provided. In general, whether or not coolant is circulated through a coolant loop coupled to the ESS depends on the difference between the ambient temperature and a preset temperature, the preset temperature typically corresponding to the temperature of the ESS. | 08-26-2010 |
20100212339 | Intelligent temperature control system for extending battery pack life - A method and apparatus for actively cooling the battery pack of an electric vehicle after the vehicle has been turned off, thereby limiting the adverse effects of temperature on battery life, are provided. Different battery pack cooling techniques are provided, thus allowing the cooling technique used in a particular instance to be selected not only based on the thermal needs of the battery pack, but also on the thermal capacity and energy requirements of the selected approach. | 08-26-2010 |
20100273034 | Battery pack enclosure with controlled thermal runaway release system - A battery pack thermal management system is provided that is comprised of at least one enclosure failure port integrated into at least one wall of a battery pack enclosure, where the enclosure failure port(s) remains closed during normal operation of the battery pack, and opens during a battery pack thermal runaway event, thereby providing a flow path for hot gas generated during the thermal runaway event to be exhausted out of the battery pack enclosure in a controlled fashion. | 10-28-2010 |
20100302051 | Battery thermal event detection system using a thermally interruptible electrical conductor - A method and apparatus is provided for determining when a battery, or one or more batteries within a battery pack, undergoes an undesired thermal event such as thermal runaway. The system uses a conductive member mounted in close proximity to, or in contact with, an external surface of the battery or batteries to be monitored. A resistance measuring system such as a continuity-tester or an ohmmeter is coupled to the conductive member, the resistance measuring system outputting a first signal when the temperature corresponding to the battery or batteries is within a prescribed temperature range and a second signal when the temperature exceeds a predetermined temperature that falls outside of the prescribed temperature range. | 12-02-2010 |
20100316894 | Integrated battery pressure relief and terminal isolation system - A system for integrating the venting feature of a battery with a means for simultaneously disconnecting the cell from the battery pack, thereby isolating the cell, is provided. The provided battery interconnect system is comprised of a battery, a connector plate for electrically coupling the battery to a battery pack, and an interruptible electrical connector for electrically coupling the connector plate to a battery terminal vent. The vent, defined by scoring on the battery terminal, ruptures when the internal battery pressure exceeds the predefined battery operating range, causing the interruptible electrical connector to break and disrupt electrical continuity between the connector plate and the battery terminal. | 12-16-2010 |
20110014506 | Method and Apparatus for Maintaining Cell Wall Integrity Using a High Yield Strength Outer Sleeve - A method and apparatus is provided in which a pre-formed sleeve or pre-formed secondary can comprised of one or more layers of a high yield strength material is positioned around the pre-formed battery case, the pre-formed sleeve/secondary can inhibiting the flow of hot, pressurized gas from within the battery through perforations formed in the battery casing during a thermal runaway event. | 01-20-2011 |
20110014514 | Cell with an Outer Layer of Intumescent Material - A battery assembly is provided that includes a layer of intumescent material that coats the sidewall and bottom surface of the cell casing, excluding at least one case contact region. | 01-20-2011 |
20110076538 | Method and apparatus for the external application of a battery pack adhesive - A method and apparatus for simplifying battery pack assembly that allows inspection of the cell-to-housing bonding region is provided. In particular, a battery pack housing member is provided that includes an interior surface that partially defines the interior region of the battery pack and that includes a plurality of cell mounting wells and an exterior surface that includes a plurality of bonding wells. Adhesive introduced into the bonding wells forms a mechanical bond between an exterior surface of a cell introduced into an adjacent cell mounting well and the housing member. | 03-31-2011 |
20110117403 | Battery Cell with a Center Pin Comprised of a Low Melting Point Material - A battery is provided that includes a cell case, an electrode assembly and a center pin within the electrode assembly, where the electrode assembly is wrapped around the center pin, and where the center pin is comprised of a material that is rigid within the normal operating temperature range of the battery and deforms, and/or melts, when the battery temperature exceeds the normal operating temperature range of the battery. | 05-19-2011 |
20110165446 | Corrosion resistant cell mounting well - A battery mounting structure, preferably for use within a battery pack housing, is provided that prevents condensation-induced corrosion from occurring between the terminals of a battery. | 07-07-2011 |
20110174556 | Battery Pack Gas Exhaust System - A thermal management system is provided that minimizes the effects of thermal runaway within a battery pack. The system is comprised of a multi-sided, substantially airtight battery pack enclosure configured to hold a plurality of batteries, where at least one side of the battery pack enclosure includes at least one cavity. An inner wall of the enclosure includes a plurality of perforations configured to pass gas from within the enclosure to the cavity within the at least one side member. The system is further comprised of at least one gas exhaust port integrated into an outer wall of the enclosure and configured to pass gas from within the cavity of the enclosure side member to the ambient environment when one or more batteries contained within the battery pack undergo thermal runaway. | 07-21-2011 |
20110206969 | Overmolded Thermal Interface for use with a Battery Cooling System - A cooling manifold assembly for use in a battery pack thermal management system is provided. The cooling manifold assembly includes a coolant tube that is interposed between at least a first row of cells and a second row of cells, where the first and second rows of cells are adjacent and preferably offset from one another. A thermal interface layer is overmolded onto the cooling tube, the thermal interface layer including a plurality of pliable fingers that extend away from the cooling tube and are interposed between the cooling tube and the first row of cells, and interposed between the cooling tube and the second row of cells, where the pliable fingers are deflected by, and in thermal contact with, the cells of the first and second rows of cells. | 08-25-2011 |
20110212356 | Extruded and Ribbed Thermal Interface for use with a Battery Cooling System - A cooling manifold assembly for use in a battery pack thermal management system is provided. The cooling manifold assembly includes a coolant tube that is interposed between at least a first row of cells and a second row of cells, where the first and second rows of cells are adjacent and preferably offset from one another. A thermal interface layer is attached to the cooling tube, the thermal interface layer including a plurality of pliable fingers that extend away from the cooling tube and are interposed between the cooling tube and the first row of cells, and interposed between the cooling tube and the second row of cells, where the pliable fingers are deflected by, and in thermal contact with, the cells of the first and second rows of cells. | 09-01-2011 |
20120013341 | Method and Apparatus for Electrically Cycling a Battery Cell to Simulate an Internal Short - A test apparatus and corresponding method for simulating an internal cell short and initiating thermal runaway in a battery cell is disclosed whereby the cell is internally heated through rapid charge and discharge cycles at high currents. The magnitude of the selected current may be modulated to simulate a cell short with the desired power profile without unrealistically heating neighboring cells or interfering with the thermal environment of the cell within the module. | 01-19-2012 |
20120021258 | Method of Controlling System Temperature to Extend Battery Pack Life - A method for actively cooling the battery pack of an electric vehicle after the vehicle has been turned off, thereby limiting the adverse effects of temperature on battery life, is provided. Different battery pack cooling techniques are provided, thus allowing the cooling technique used in a particular instance to be selected not only based on the thermal needs of the battery pack, but also on the thermal capacity and energy requirements of the selected approach. | 01-26-2012 |
20120030932 | Method of Controlled Cell-Level Fusing Within a Battery Pack - A method is provided that achieves improved battery pack performance, system reliability and system safety while impacting only a small region of the battery pack/battery module, and thus having only a minor impact on battery pack cost, complexity, weight and size. The battery pack/battery module is designed such that the fusible interconnects associated with a single battery, or a specific fusible interconnect associated with a single battery, will be the last interconnect(s) to fuse during a short circuit event. The risk of sustained arcing for the predetermined interconnect(s) is minimized through the use of rapid clearing interconnects. As a result, the risk of damage and excessive heating is also minimized. | 02-09-2012 |
20120034497 | Battery Pack with Cell-Level Fusing - A battery pack, or battery pack module, is provided that achieves improved battery pack performance, system reliability and system safety while impacting only a small region of the battery pack/battery module, and thus having only a minor impact on battery pack cost, complexity, weight and size. The battery pack/battery module is designed such that the fusible interconnects associated with a single battery, or a specific fusible interconnect associated with a single battery, will be the last interconnect(s) to fuse during a short circuit event. The risk of sustained arcing for the predetermined interconnect(s) is minimized through the use of rapid clearing interconnects. As a result, the risk of damage and excessive heating is also minimized. | 02-09-2012 |
20120034501 | Battery Pack Configuration to Reduce Hazards Associated with Internal Short Circuits - A battery pack, or battery pack module, is provided that is configured to respond to a short circuit of moderate current in a manner that minimizes the risk of an initial thermal runaway event propagating throughout the battery pack/battery pack module. In general, the battery pack/battery module allows pre-selection of which cell of the cells comprising the battery pack/battery pack module will be the last cell to respond to the short circuit. As a result, a thermal isolation barrier may be used to separate the preselected cell from the other cells of the battery pack/battery pack module, thereby minimizing the risk of excessive heating and extensive collateral damage. | 02-09-2012 |
20120040210 | Thermal Energy Transfer System for a Power Source Utilizing Both Metal-Air and Non-Metal-Air Battery Packs - A power source comprised of a metal-air battery pack and a non-metal-air battery pack is provided, wherein thermal energy from the metal-air battery pack is used to heat the non-metal-air battery pack. In one aspect, a thermal energy transfer system is provided that controls the flow of thermal energy from the metal-air battery pack to the non-metal-air battery pack. In another aspect, the flow of thermal energy from the metal-air battery pack to the non-metal-air battery pack is controlled and used to heat the non-metal-air battery pack prior to charging the non-metal-air battery pack. | 02-16-2012 |
20120040212 | Hazard Mitigation Within a Battery Pack Using Metal-Air Cells - A system and method for mitigating the effects of a thermal event within a battery pack is provided in which the hot gas and material generated during the thermal runaway of at least one non-metal-air cell of a plurality of non-metal-air cells is directed through one or more metal-air cells, the metal-air cells absorbing at least a portion of the thermal energy generated during the event before it is released to the ambient environment. As a result, the risks to vehicle passengers, bystanders, first responders and property are limited. | 02-16-2012 |
20120040253 | Collection, Storage and Use of Metal-Air Battery Pack Effluent - A system and method for collecting, storing and using the oxygen-rich effluent generated when charging a metal-air battery pack is provided. | 02-16-2012 |
20120040255 | Hazard Mitigation Through Gas Flow Communication Between Battery Packs - A system and method for mitigating the effects of a thermal event within a non-metal-air battery pack is provided in which the hot gas and material generated during the event is directed into the metal-air cells of a metal-air battery pack. The metal-air cells provide a large thermal mass for absorbing at least a portion of the thermal energy generated during the event before it is released to the ambient environment. As a result, the risks to vehicle passengers, bystanders, first responders and property are limited. | 02-16-2012 |
20120041622 | Charge Rate Modulation of Metal-Air Cells as a Function of Ambient Oxygen Concentration - A system and method for charging a metal-air battery pack at the maximum possible rate while maintaining an ambient oxygen concentration below a preset concentration is provided, thereby minimizing the risks associated with generating oxygen during the charging cycle. | 02-16-2012 |
20120041623 | Charge Rate Modulation of Metal-Air Cells as a Function of Ambient Oxygen Concentration - A system and method for charging a metal-air battery pack at the maximum possible rate while maintaining an ambient oxygen concentration below a preset concentration is provided, thereby minimizing the risks associated with generating oxygen during the charging cycle. | 02-16-2012 |
20120041628 | Control, Collection and Use of Metal-Air Battery Pack Effluent - A system and method for maintaining an ambient oxygen concentration below a preset concentration while charging a metal-air battery pack is provided, the system utilizing an on-board means for collecting and storing the oxygen-rich effluent generated during the charge cycle. | 02-16-2012 |
20120046815 | Method for Optimizing Battery Pack Temperature - A method for limiting the adverse effects of temperature on the electrical energy storage system (ESS) of an electric vehicle after the vehicle has been turned off is provided. In general, whether or not coolant is circulated through a coolant loop coupled to the ESS depends on the difference between the ambient temperature and a preset temperature, the preset temperature typically corresponding to the temperature of the ESS. | 02-23-2012 |
20120105015 | Battery Pack Overcharge Protection System - An overcharge protection device (OPD) is provided that may be used alone, or in combination with conventional charging protection systems, to protect a battery pack from the occurrence of a potentially damaging overcharging event. The OPD is designed to be coupled to, and interposed between, the terminals of the battery pack. During normal system operation, the OPD has no effect on the operation of the charging system or the battery pack. During an overcharging event, if overcharging is not prevented by another conventional system, the OPD of the invention creates a short across the terminals of the battery pack causing a battery pack fuse designed to provide battery pack short circuit protection to blow, thereby interrupting the current path from the charger to the battery pack and preventing the battery pack from being overcharged. | 05-03-2012 |
20120153901 | Method of Withdrawing Heat from a Battery Pack - A method for withdrawing heat from a battery pack is provided, wherein the heat is transferred from at least one electrode of each cell comprising the battery pack, via an electrically and thermally conductive tab, through a current collector plate and through a thermal interface layer to a temperature control panel that is coupled to an external temperature control system. | 06-21-2012 |
20120183826 | Apparatus for the External Application of Battery Pack Encapsulant - An apparatus for simplifying battery pack encapsulation is provided. The battery pack includes a pair of complementary housing members with each housing member including a plurality of cell constraints into which the ends of corresponding battery cells are inserted during assembly. One or both housing members also include at least one, and preferably a plurality, of raised encapsulant injection ports. The raised encapsulant injection ports are designed to extend above the surface of the respective housing members and beyond the injected encapsulation material, thus ensuring that the ports remain open after encapsulation material injection. | 07-19-2012 |
20120231306 | Battery Pack Venting System - A thermal management system is provided that minimizes the effects of thermal runaway within a battery pack. The system is comprised of a sealed battery pack enclosure configured to hold a plurality of batteries, where the battery pack enclosure is divided into a plurality of sealed battery pack compartments. The system also includes a plurality of battery venting assemblies, where at least one battery venting assembly is integrated into each of the sealed battery pack compartments, and where each of the battery venting assemblies includes an exhaust port integrated into an outer wall of the battery pack compartment and a valve, the valve being configured to seal the exhaust port under normal operating conditions and to unseal the exhaust port when at least one of the batteries within the battery pack compartment enters into thermal runaway. | 09-13-2012 |
20120237803 | Battery Pack Directed Venting System - A thermal management system is provided that minimizes the effects of thermal runaway within a battery pack, the system using an integrated battery venting assembly comprised of an integrated exhaust port, a valve retention plate that covers the exhaust port and includes a plurality of retention plate ports, and a plurality of valves that are configured to seal the retention plate ports under normal conditions and unseal the retention plate ports during thermal runaway. As hot gas passes through the retention plate ports, the plate is configured to melt and be ejected, thereby allowing subsequent hot gas to pass through the larger exhaust port. A perforated cover plate may be used to protect the external surfaces of the retention plate and valves. An internally mounted exhaust guide may be used to direct the flow of hot gas expelled during the thermal runaway event. | 09-20-2012 |
20120270080 | Integrated Battery Pressure Relief and Terminal Isolation System - A system for integrating the venting feature of a battery with a means for simultaneously disconnecting the cell from the battery pack, thereby isolating the cell, is provided. The provided battery interconnect system is comprised of a battery, a connector plate for electrically coupling the battery to a battery pack, and an interruptible electrical connector for electrically coupling the connector plate to a battery terminal vent. The venting region, defined by scoring on the battery terminal, ruptures when the internal battery pressure exceeds the predefined battery operating range, causing the interruptible electrical connector to break and disrupt electrical continuity between the connector plate and the battery terminal. | 10-25-2012 |
20120308857 | Method and Apparatus for Maintaining Cell Wall Integrity Using a High Yield Strength Outer Casing - A method and apparatus is provided in which a pre-formed secondary can comprised of one or more layers of a high yield strength material is positioned around the pre-formed battery case, the pre-formed secondary can inhibiting the flow of hot, pressurized gas from within the battery through perforations formed in the battery casing during a thermal runaway event. | 12-06-2012 |
20120308858 | Battery Pack Enclosure with Controlled Thermal Runaway Release System - A battery pack thermal management system is provided that is comprised of at least one enclosure failure port integrated into at least one wall of a battery pack enclosure, where the enclosure failure port(s) remains closed during normal operation of the battery pack, and opens during a battery pack thermal runaway event, thereby providing a flow path for hot gas generated during the thermal runaway event to be exhausted out of the battery pack enclosure in a controlled fashion. | 12-06-2012 |
20120308859 | Battery Pack Enclosure with Controlled Thermal Runaway Release System - A battery pack thermal management system is provided that is comprised of at least one enclosure failure port integrated into at least one wall of a battery pack enclosure, where the enclosure failure port(s) remains closed during normal operation of the battery pack, and opens during a battery pack thermal runaway event, thereby providing a flow path for hot gas generated during the thermal runaway event to be exhausted out of the battery pack enclosure in a controlled fashion. | 12-06-2012 |
20130004820 | Battery Coolant Jacket - A battery coolant jacket for use with a plurality of cells is provided, the jacket comprised of a hollow enclosure configured to permit a liquid coolant to flow through the enclosure, entering via a coolant inlet and exiting via a coolant outlet; a plurality of cell apertures that extend completely through the hollow enclosure, where each cell aperture is sized to fit a cell; and a plurality of coolant segregation walls that are integrated into the hollow enclosure and separate the cells into groups of cells, and where each coolant segregation wall forms a barrier between the cell group contained within that coolant segregation wall and the liquid coolant flowing through the hollow enclosure. The coolant jacket may include at least one flow control wall integrated within the hollow enclosure that controls the coolant flow pathway between the enclosure's coolant inlet and outlet, for example causing the coolant flow pathway to alternate directions between adjacent cell groups. | 01-03-2013 |
20130015823 | Charge Rate Modulation of Metal-Air Cells as a Function of Ambient Oxygen Concentration - A method for charging a metal-air battery pack at the maximum possible rate while maintaining an ambient oxygen concentration below a preset concentration is provided, thereby minimizing the risks associated with generating oxygen during the charging cycle. | 01-17-2013 |
20130066504 | Dual Mode Range Extended Electric Vehicle - A dual mode battery charging system and method of use are provided for use in an electric vehicle. The system utilizes at least two user selectable, charging operational modes. In a first operational mode, a state of charge circuit powers on the engine/generator system whenever the battery state of charge falls below a first level and until the battery state of charge reaches a second level, where the second level is higher than the first level. In a second operational mode, the state of charge circuit powers on the engine/generator system whenever the battery state of charge falls below a third level and until the battery state of charge reaches a fourth level, where the fourth level is higher than the third level, and where both the third and fourth levels are lower than both the first and second levels. | 03-14-2013 |
20130066505 | Dual Mode Range Extended Electric Vehicle - A dual mode battery charging system and method of use are provided for use in an electric vehicle. The system utilizes at least two user selectable, charging operational modes. In a first operational mode, a state of charge circuit cycles an engine/generator system on/off between a first level and a second level, where the second level is higher than the first level. In a second operational mode, the state of charge circuit cycles the engine/generator system on/off between a third level and a fourth level. After the fourth state of charge has been reached once, the state of charge circuit cycles the engine/generator system on/off between a fifth level and the fourth level, where the fifth level is higher than the third level and lower than the fourth level, and where the fourth level is lower than both the first and second levels. | 03-14-2013 |
20130066506 | Dual Mode Range Extended Electric Vehicle - A dual mode battery charging system and method of use are provided for use in an electric vehicle. The system utilizes at least two user selectable, charging operational modes. In a first operational mode, a state of charge circuit powers on the engine/generator system whenever the battery state of charge falls below a first level and until the battery state of charge reaches a second level, where the second level is higher than the first level. In a second operational mode, the state of charge circuit powers on the engine/generator system whenever the battery state of charge falls below a third level and until the battery state of charge reaches the second level, where the third level is lower than both the first and second levels. | 03-14-2013 |
20130071701 | Response to High Voltage Electrolysis of Coolant in a Battery Pack - An apparatus and method providing for detecting and responding to high voltage electrolysis within an electric vehicle battery enclosure to limit possible excessive thermal condition of the individual battery cells and modules. A microprocessor-implemented response system for high voltage electrolysis in a battery pack an evaluator to monitor, using the microprocessor, a high voltage electrolysis flag indicative of a possible high voltage electrolysis within an enclosure including a plurality of electrically-coupled battery modules storing energy for the battery pack and a coolant distribution system disposed among and electrically isolated from the plurality of battery modules; and a remediation system, coupled to the enclosure and responsive to the possible high voltage electrolysis when the evaluator detects a likelihood of the possible high voltage electrolysis, to decrease risks associated with the possible high voltage electrolysis when operated. | 03-21-2013 |
20130073229 | Detection of High Voltage Electrolysis of Coolant in a Battery Pack - An apparatus and method providing for detecting and responding to high voltage electrolysis within an electric vehicle battery enclosure to limit possible excessive thermal condition of the individual battery cells and modules. The present invention includes embodiments directed towards detection algorithms and apparatus for promoting the use of voltage, current, humidity, temperature, and pressure sensors for the purpose of detecting high voltage electrolysis. Additionally, the present invention includes response processes and structures to address high-voltage electrolysis. | 03-21-2013 |
20130073233 | Detection of Low Voltage Electrolysis in a Battery Pack - An apparatus and method providing for detecting and responding to low voltage electrolysis within an electric vehicle battery detecting and responding to low voltage electrolysis within an electric vehicle battery enclosure to limit a possible hazard condition of battery enclosure. The present invention includes embodiments directed towards detection algorithms and apparatus for promoting the use of sensors (e.g., hydrogen, voltage, current, and immersion sensors) for the purpose of detecting low voltage electrolysis. Additionally, the present invention includes response processes and structures to address low voltage electrolysis. | 03-21-2013 |
20130073234 | Response to Low Voltage Electrolysis in a Battery Pack - An apparatus and method providing for detecting and responding to low voltage electrolysis within an electric vehicle battery detecting and responding to low voltage electrolysis within an electric vehicle battery enclosure to limit a possible hazard condition of battery enclosure. A microprocessor-implemented response system for low voltage electrolysis in a battery pack, includes an evaluator to monitor, using the microprocessor, a low voltage electrolysis flag indicative of a possible low voltage electrolysis of fluid within an enclosure that generates a flammable gas including a plurality of electrically-coupled battery modules storing energy for the battery pack; and a remediation system, coupled to the enclosure and responsive to the possible low voltage electrolysis when the evaluator detects a likelihood of the possible low voltage electrolysis, to decrease risks associated with the possible low voltage electrolysis when the remediation system is active. | 03-21-2013 |
20130078494 | Rigid Cell Separator for Minimizing Thermal Runaway Propagation within a Battery Pack - A spacer assembly, comprised of a plurality of rigid spacers, is provided that is configured for use with a cell mounting bracket within a battery pack. The spacer assembly maintains the positions of the batteries within the battery pack during a thermal event and after the cell mounting bracket loses structural integrity due to the increased temperature associated with the thermal event. By keeping the battery undergoing thermal runaway in its predetermined location within the battery pack, the minimum spacing between cells is maintained, thereby helping to minimize the thermal effects on adjacent cells while ensuring that the cooling system, if employed, is not compromised. As a result, the risk of thermal runaway propagation is reduced. | 03-28-2013 |
20130179012 | DETECTION OF OVER-CURRENT IN A BATTERY PACK - A controller identifies a condition of a hazardous internal short by comparing patterns of series element voltages to the last known balance condition of the series elements. If the loaded or resting voltage of one or more contiguous series elements uniformly drop from the previously known condition by an amount consistent with an over-current condition, an over-current internal short circuit fault is registered. The desired response is to prevent the affected series elements from heating to a hazardous temperature by summoning the maximum heat rejection capability of the system until the short ceases and the affected elements cool, the cooling function is no longer able to operate due to low voltage, or the affected series string has drained all of its energy through the short. Also includes are responses that allow the battery pack to continue to power the cooling system even though it may enter an over-discharged state. | 07-11-2013 |
20130194716 | SOLID STATE ENERGY STORAGE DEVICES - Described in this patent application are devices for energy storage and methods of making and using such devices. In various embodiments, blocking layers are provided between dielectric material and the electrodes of an energy storage device. The block layers are characterized by higher dielectric constant than the dielectric material. There are other embodiments as well. | 08-01-2013 |
20130221916 | Electric Vehicle Battery Lifetime Optimization Operational Mode - A multi-mode operating system for an electric vehicle is provided, the system including means for a user to select a preferred mode of operation from a plurality of operational modes that include at least a Battery Life mode and a Standard mode, wherein the Battery Life mode is configured to select operating and charging parameters that emphasize battery health and battery life over vehicle range and/or vehicle performance. The system includes a thermal management system for maintaining the vehicle's battery pack to within any of a plurality of temperature ranges, and a charging system for charging the vehicle's battery pack to any of a plurality of minimum and maximum SOC levels and at any of a plurality of charging rates. | 08-29-2013 |
20130221928 | Electric Vehicle Battery Lifetime Optimization Operational Mode - A method of setting the operational mode of an electric vehicle is provided, where the operational mode is selected from a plurality of operational modes that include at least a Battery Life mode and a Standard mode, wherein the Battery Life mode is configured to select operating and charging parameters that emphasize battery health and battery life over vehicle range and/or vehicle performance. The system includes a thermal management system for maintaining the vehicle's battery pack to within any of a plurality of temperature ranges, and a charging system for charging the vehicle's battery pack to any of a plurality of minimum and maximum SOC levels and at any of a plurality of charging rates. | 08-29-2013 |
20130273444 | Hazard Mitigation Within a Battery Pack Using Metal-Air Cells - A system and method for mitigating the effects of a thermal event within a battery pack is provided in which the hot gas and material generated during the thermal runaway of at least one non-metal-air cell of a plurality of non-metal-air cells is directed through one or more metal-air cells, the metal-air cells absorbing at least a portion of the thermal energy generated during the event before it is released to the ambient environment. As a result, the risks to vehicle passengers, bystanders, first responders and property are limited. | 10-17-2013 |
20130328531 | Charge Rate Modulation of Metal-Air Cells as a Function of Ambient Oxygen Concentration - A method for charging a metal-air battery pack at the maximum possible rate while maintaining an ambient oxygen concentration below a preset concentration is provided, thereby minimizing the risks associated with generating oxygen during the charging cycle. | 12-12-2013 |
20140091748 | BATTERY CONTROL SYSTEMS - Various embodiments herein provide methods and apparatus for conditioning a battery. The conditioning may be undertaken to restore charge capacity or power capability, especially when practiced on a battery having a lithium negative electrode and/or a positive electrode having a conversion material. In one embodiment, the conditioning method includes applying a substantially constant current or power until a conditioning voltage is reached, where the conditioning voltage is higher than the maximum voltage used during normal cycling. The method further includes continuing to charge the battery at the conditioning voltage until a maximum conditioning charge is reached. Next, the method includes discharging the battery to about the maximum charge voltage prior to using the battery in an end use. Also provided is a conditioning apparatus that is configured to perform the conditioning method. | 04-03-2014 |
20140093760 | BATTERY CONTROL SYSTEMS - Various embodiments herein relate to the design of battery stacks, batteries and battery packs that are able to accommodate volumetric expansion in the battery materials. These designs may be especially useful in connection with batteries having negative electrodes made of lithium metal and/or positive electrodes made of an electrochemically active conversion material. These batteries may expand on the order of 10-40% during cycling. The battery designs disclosed herein include compressible regions that span a wide variety of different designs and implementations. | 04-03-2014 |
20140170493 | NANOSTRUCTURED MATERIALS FOR ELECTROCHEMICAL CONVERSION REACTIONS - The disclosure is related to battery systems. More specifically, embodiments of the disclosure provide a nanostructured conversion material for use as the active material in battery cathodes. In an implementation, a nanostructured conversion material is a glassy material and includes a metal material, one or more oxidizing species, and a reducing cation species mixed at a scale of less than 1 nm. The glassy conversion material is substantially homogeneous within a volume of 1000nm | 06-19-2014 |
20140272564 | IRON, FLUORINE, SULFUR COMPOUNDS FOR BATTERY CELL CATHODES - Provided herein are energy storage device cathodes with high capacity electrochemically active material including compounds that include iron, fluorine, sulfur, and optionally oxygen. Batteries with active materials including a compound of the formula FeF | 09-18-2014 |
20140317912 | NANOSTRUCTURED MATERIALS FOR ELECTROCHEMICAL CONVERSION REACTIONS - The disclosure is related to battery systems. More specifically, embodiments of the disclosure provide a nanostructured conversion material for use as the active material in battery cathodes. In an implementation, a nanostructured conversion material is a glassy material and includes a metal material, one or more oxidizing species, and a reducing cation species mixed at a scale of less than 1 nm. The glassy conversion material is substantially homogeneous within a volume of 1000 nm | 10-30-2014 |
20140322603 | NANOSTRUCTURED MATERIALS FOR ELECTROCHEMICAL CONVERSION REACTIONS - The disclosure is related to battery systems. More specifically, embodiments of the disclosure provide a nanostructured conversion material for use as the active material in battery cathodes. In an implementation, a nanostructured conversion material is a glassy material and includes a metal material, one or more oxidizing species, and a reducing cation species mixed at a scale of less than 1 nm. The glassy conversion material is substantially homogeneous within a volume of 1000 nm | 10-30-2014 |
20140363740 | SOLID STATE ENERGY STORAGE DEVICES - Solid state energy storage systems and devices are provided. A solid state energy storage devices can include an active layer disposed between conductive electrodes, the active layer having one or more quantum confinement species (QCS), such as quantum dots, quantum particles, quantum wells, nanoparticles, nanostructures, nanowires and nanofibers. The solid state energy storage device can have a charge rate of at least about 500 V/s and an energy storage density of at least about 150 Whr/kg. | 12-11-2014 |