Abstract: A battery system including: a plurality of subunits each of which has a heatsink and a battery cell and two voltage terminals symmetrically positioned with respect to a centerline of that battery cell, wherein all of the battery cells are arranged so that their voltage terminals are aligned along two rows; a plurality of identical busbar supports equal in number to the plurality of subunits, each having two slots and mounted on a corresponding different one of the subunits with each of the terminals of the battery cell extending up through the two slots; and a plurality of bimetallic busbars, each one supported by a different corresponding subset of the busbar supports and electrically connected directly to either a first or second terminal of each of the battery cells of each of the modules on which those busbar supports are mounted.

Abstract: A compact, robust, multifunctional and highly manufacturable rechargeable battery cell is provided. The cell design dedicates minimal internal volume to inert components of the cell. This is accomplished, in part, by providing multiple functionalities to individual cell components.

Abstract: A battery module is disclosed where the battery module includes a variety of internal components. In one example, microcellular polyurethane pads are positioned between walls of the battery module and internal components of the battery module to reduced degradation that may be caused by operating the battery module in a vehicle. The pads may reduce vibration and interference between the battery module walls and interior battery components so that battery module life may be extended.

Abstract: A method of controlling current in a parallel battery systems includes providing at least two parallel connected batteries, each said battery having an internal resistance and dissipating heat while operating; during operation, measuring at least the temperature and current of each individual battery; and providing instructions to a temperature control system having a temperature control module coupled with each said battery for individually cooling each said battery to adjust temperature of at least one battery in order to maintain the current at a target value.

Abstract: Systems and methods for controlling a contactor of a battery pack are disclosed. In one embodiment, the coil of the contactor is controlled by a power supply. Further, the contactor coil holding current may be adjusted in response to vehicle drive mode.

Abstract: An electrochemical cell has first and second electroactive layers, a heterogeneous ohmic contact, and a homogeneous ohmic contact. The heterogeneous ohmic contact includes dissimilar first and second conductors, with the first conductor joined to the first electroactive layer and the second conductor oriented opposite the first electroactive layer. The homogeneous ohmic contact includes the second conductor, joined to the second electroactive layer.

Abstract: An electrode has a front face furthest from the current collector and a back face closest to the current collector and Is disposed on the current collector, and the electrode has a primary gradient of one of a chemical, physical and performance properties of the electroactive particle composition between the front and back faces, with the proviso that the primary gradient is not a bulk porosity gradient. In some embodiments, the electrode further comprises one or more secondary gradients Imposed over the primary gradient.

Abstract: Systems and methods for assessing voltage threshold detection circuitry of individual battery cells within a battery pack supplying power to a vehicle are disclosed. One example system comprises, a plurality of battery cells within a battery pack, a plurality of voltage threshold detecting circuits detecting voltage of the plurality of battery cells, a voltage of a first battery cell of the plurality of battery cells coupled to a first voltage threshold detecting circuit of the plurality of voltage threshold detecting circuits, and a network that selectively couples a second battery cell to the first voltage detecting circuit while the first battery cell is coupled to the first voltage detecting circuit.

Abstract: A nanocomposite electrode that includes a current collector, an electroactive layer a conductive adhesive contacting the surface of the current collector and an interlayer region in electrical communication with the current collector and the electroactive material. The interlayer region is interposed between the current collector and the electroactive layer and includes a portion of the conductive adhesive intermixed with a portion of the electroactive layer. The electroactive layer includes electroactive material having a surface area of at least about 10 m2/g. The conductive adhesive may be at least partially soluble in electrode casting solvent. Electrochemical devices, such as lithium secondary cells, containing an electrode with an interlayer region are also provided, as are processes for making such electrodes and electrochemical devices.

Abstract: Nanoscale ion storage materials are provided that exhibit unique properties measurably distinct from their larger scale counterparts. For example, the nanoscale materials can exhibit increased electronic conductivity, improved electromechanical stability, increased rate of intercalation, and/or an extended range of solid solution. Useful nanoscale materials include alkaline transition metal phosphates, such as LiMPO4, where M is one or more transition metals. The nanoscale ion storage materials are useful for producing devices such as high energy and high power storage batteries, battery-capacitor hybrid devices, and high rate electrochromic devices.

Abstract: A system for supplying power internal to a battery pack is disclosed. In one embodiment, the system includes a power supply that is powered by battery cells in the battery pack such that each battery cell supplies substantially the same amount of current to power the power supply. In this way, power can be distributed within the battery pack without causing imbalance between an amount of charge stored in different battery cells.

Abstract: A method for estimating the state of a battery having multiple cells is disclosed. In one embodiment, strain gauges are coupled to battery binding bands that hold cells of the battery together. The strain measured by the gauges may be related to the electrical charge stored by the battery. The method may improve estimates of battery state of charge during conditions when battery voltage changes little and the battery continues to accept charge.

Abstract: Systems and methods for a scalable battery controller are disclosed. In one example, a circuit board coupled to a battery cell stack is designed to be configurable to monitor and balance battery cells of battery cell stacks that may vary depending on battery pack requirements. Further, the battery pack control module may configure software instructions in response to a voltage at a battery cell stack.

Abstract: Systems and methods for detecting and managing a plurality of cells within a battery pack supplying power to propel a vehicle are disclosed. One example method comprises, monitoring voltage of a plurality of battery cells of a battery pack, activating a power supply when a voltage of at least one battery cell of the plurality of battery cells exceeds a threshold, and draining a portion of charge from the at least one battery cell.

Abstract: Amorphous or partially amorphous nanoscale ion storage materials are provided. For example, lithium transition metal phosphate storage compounds are nanoscale and amorphous or partially amorphous in an as-prepared state, or become amorphous or partially amorphous upon electrochemical intercalation or de-intercalation by lithium. These nanoscale ion storage materials are useful for producing devices such as high energy and high power storage batteries.

Abstract: A battery management system includes one or more lithium ion cells in electrical connection, each said cell comprising: first and second working electrodes and one or more reference electrodes, each reference electrode electronically isolated from the working electrodes and having a separate tab or current collector exiting the cell and providing an additional terminal for electrical measurement; and a battery management system comprising a battery state-of-charge monitor, said monitor being operable for receiving information relating to the potential difference of the working electrodes and the potential of one or more of the working electrodes versus the reference electrode.

Abstract: A battery system including: a plurality of subunits each of which has a heatsink and a battery cell and two voltage terminals symmetrically positioned with respect to a centerline of that battery cell, wherein all of the battery cells are arranged so that their voltage terminals are aligned along two rows; a plurality of identical busbar supports equal in number to the plurality of subunits, each having two slots and mounted on a corresponding different one of the subunits with each of the terminals of the battery cell extending up through the two slots; and a plurality of bimetallic busbars, each one supported by a different corresponding subset of the busbar supports and electrically connected directly to either a first or second terminal of each of the battery cells of each of the modules on which those busbar supports are mounted.

Abstract: A battery comprises a battery cell having two voltage terminals and a flexible sidewall; a wall structure against which the battery cell is located, the wall structure including a sidewall that is adjacent to the sidewall of the battery cell; and a tooth structure that extends away from the sidewall of the wall structure and towards the sidewall of the battery cell, wherein the tooth structure includes a distal end sufficiently sharp to puncture the flexible sidewall of the battery cell when the flexible sidewall of the battery cell is forced up against the tooth structure due to a build up of excess pressure inside the battery cell.

Abstract: An electrochemical device includes a first electrode in electrical communication with a first current collector, a second electrode in electrical communication with a second current collector and a crosslinked solid polymer in contact with the first and second electrodes. At least one of the first and second electrodes includes a network of electrically connected particles comprising an electroactive material, and the particles of one electrode exert a repelling force on the other electrode when the first and second electrodes are combined with an uncrosslinked precursor to the solid polymer.

Abstract: Materials useful as electrodes for lithium batteries have very good electronic and ionic conductivities. They are fabricated from a starting mixture which includes a metal, a phosphate ion, and an additive which enhances the transport of lithium ions in the resultant material. The mixture is heated in a reducing environment to produce the material. The additive may comprise a pentavalent metal or a carbon. In certain embodiments the material is a two-phase material. Also disclosed are electrodes which incorporate the materials and lithium batteries which incorporate those electrodes.