Abstract: A modular current interrupt device includes an electrically-conductive rupture disc, an electrically-conductive pressure disc attached to the rupture disc to form an electrical pathway. An electrically-insulating ring partitions a perimeter of the rupture disc from a perimeter of the pressure disc, and a seating element secures the electrically-insulated ring to the pressure disc. At least one of the rupture disc and electrically-insulating ring defines a conduit, whereby exposure of one side of the pressure disc to sufficient force through the conduit causes the pressure disc to separate from the rupture disc to thereby sever the electrical pathway. A low pressure current interrupt device (CID) activates at a minimal threshold internal gauge pressure in a range of, for example, between about 4 kg/cm2 and about 9 kg/cm2.

Abstract: A battery includes a cell casing that has recessed portion on a major surface of the casing, the recessed portion being substantially planar and bordering a remainder of the major surface at a ridge portion on each of one or two sides of the recessed portion, whereby the recessed portion, the ridge portions, and the remainder of the major surface cooperate under an increase of gauge pressure to cause a plane defined by a boundary between the ridge portions and the remainder of the major surface to move.

Abstract: A battery cell connector for a battery module includes a pair of cantilevered arms and base portions that are linked at the base portion by a bridge. An interconnect board for connecting a plurality of battery cells includes a circuit board and a plurality of battery cell connectors. A battery block system includes a battery block that has a tray and a plurality of battery cells, and an interconnect board in mating relationships with the tray. A battery system includes first and second bus bars, a first and second pluralities of battery cells, and an interconnect board having a plurality of battery cell connectors linking the first and second plurality of battery cells.

Abstract: Adjacent battery cells connected in devices are balanced by closing a first circuit to charge an energy storage device from a first battery cell and thereafter simultaneously opening the first isolated switch and closing a second isolated switch to cause the energy storage device to charge a second battery cell. A circuit includes an isolated switch that operates simultaneously to balance battery cells connected in series, and a battery system balances battery modules connected in series, the battery module including battery cells connected in series. The battery cells and modules can be balanced by hierarchical balancing of modules of the battery pack and component cells of the modules.

Abstract: A battery includes a cell casing that has recessed portion on a major surface of the casing, the recessed portion being substantially planar and bordering a remainder of the major surface at ridge portions on at least three sides of the recessed portion, whereby the recessed portion, the ridge portions, and the remainder of the major surface cooperate under an increase of gauge pressure to cause a plane defined by a boundary between the ridge portions and the remainder of the major surface to move.

Abstract: A battery cell connector for a battery module includes a pair of cantilevered arms and base portions that are linked at the base portion by a bridge. An interconnect board for connecting a plurality of battery cells includes a circuit board and a plurality of battery cell connectors. A battery block system includes a battery block that has a tray and a plurality of battery cells, and an interconnect board in mating relationships with the tray. A battery system includes first and second bus bars, a first and second pluralities of battery cells, and an interconnect board having a plurality of battery cell connectors linking the first and second plurality of battery cells.

Abstract: A battery block includes a first prismatic battery cell defining a first substantially planar surface, a second prismatic battery cell defining a second substantially planar surface, the second substantially planar surface being in opposing relation to the first substantially planar surface, and a thermal barrier suspended between the first and second substantially planar surfaces, wherein the thermal barrier is spaced from both the first and second substantially planar surfaces.

Abstract: In one embodiment, an active cathode material comprises a mixture that includes: at least one of a lithium cobaltate and a lithium nickelate; and at least one of a manganate spinel represented by an empirical formula of Li(1+x1)(Mn1?y1A?y1)2?x1Oz1 and an olivine compound represented by an empirical formula of Li(1?x2)A?x2MPO4. In another embodiment, an active cathode material comprises a mixture that includes: a lithium nickelate selected from the group consisting of LiCoO2-coated LiNi0.8Co0.15Al0.05O2, and Li(Ni1/3Co1/3Mn1/3)O2; and a manganate spinel represented by an empirical formula of Li(1+x7)Mn2?y7Oz7. A lithium-ion battery and a battery pack each independently employ a cathode that includes an active cathode material as described above.

Abstract: A modular current interrupt device includes an electrically-conductive rupture disc, an electrically-conductive pressure disc attached to the rupture disc to form an electrical pathway. An electrically-insulating ring partitions a perimeter of the rupture disc from a perimeter of the pressure disc, and a seating element secures the electrically-insulated ring to the pressure disc. At least one of the rupture disc and electrically-insulating ring defines a conduit, whereby exposure of one side of the pressure disc to sufficient force through the conduit causes the pressure disc to separate from the rupture disc to thereby sever the electrical pathway. A low pressure current interrupt device (CID) activates at a minimal threshold internal gauge pressure in a range of, for example, between about 4 kg/cm2 and about 9 kg/cm2.

Abstract: The methods in this disclosure allow for the identification, selection, and arrangement of cells, blocks, and modules in large scale battery systems, such as electric vehicle battery systems. An example embodiment of the present invention allows for the identification of the cells, blocks, and modules with a unique identifier or associated parameter (e.g., internal resistance contributions or capacity). Additionally, to form a block, cells may be selected from a group of capacity-range sorting bins. Based on a parameter of the cell, a pseudo-number generator may be also be used to select cells from an available inventory of cells as maintained in a cell database based. Cells may also be placed in a block for uniform effective cell impedance and even cell aging while minimizing overall block capacity degradation caused by cycling. Block capacities may also be computed based on a known average temperature gradient during operation.

Abstract: A low pressure current interrupt device (CID) activates at a minimal threshold internal gauge pressure. Preferably, the CID includes a first conductive plate and a second conductive plate in electrical communication with the first conductive plate, the electrical communication between the first and the second conductive plates being interrupted at the minimal threshold internal gauge pressure. The first conductive plate can include a frustum having a first end and a second end, a base extending radially from a perimeter of the first end of the frustum, and an essentially planar cap sealing the second end of the frustum. The first end has a broader diameter than the second end, and the second conductive plate is in electrical contact with the essentially planar cap through a weld.

Abstract: A modular current interrupt device includes an electrically-conductive rupture disc, an electrically-conductive pressure disc attached to the rupture disc to form an electrical pathway. An electrically-insulating ring partitions a perimeter of the rupture disc from a perimeter of the pressure disc, and a seating element secures the electrically-insulated ring to the pressure disc. At least one of the rupture disc and electrically-insulating ring defines a conduit, whereby exposure of one side of the pressure disc to sufficient force through the conduit causes the pressure disc to separate from the rupture disc to thereby sever the electrical pathway. A low pressure current interrupt device (CID) activates at a minimal threshold internal gauge pressure in a range of, for example, between about 4 kg/cm2 and about 9 kg/cm2.

Abstract: A secondary lithium-ion battery employing a prismatic battery can includes a cathode that includes a mixture of lithium nickel cobalt manganese oxide and a lithium nickel cobalt oxide in a weight ratio of between about 0.20:0.80 and about 0.80:0.20, and a current interrupt device. The cathode and current interrupt device are attenuated to trigger the current interrupt device when a voltage of greater than about 4.2 volts and equal to or less than about 5.0 volts is applied to the secondary lithium battery.

Abstract: The methods in this disclosure allow for the identification, selection, and arrangement of cells, blocks, and modules in large scale battery systems, such as electric vehicle battery systems. An example embodiment of the present invention allows for the identification of the cells, blocks, and modules with a unique identifier or associated parameter (e.g., internal resistance contributions or capacity). Additionally, to form a block, cells may be selected from a group of capacity-range sorting bins. Based on a parameter of the cell, a pseudo-number generator may be also be used to select cells from an available inventory of cells as maintained in a cell database based. Cells may also be placed in a block for uniform effective cell impedance and even cell aging while minimizing overall block capacity degradation caused by cycling. Block capacities may also be computed based on a known average temperature gradient during operation.

Abstract: Adjacent battery cells connected in devices are balanced by closing a first circuit to charge an energy storage device from a first battery cell and thereafter simultaneously opening the first isolated switch and closing a second isolated switch to cause the energy storage device to charge a second battery cell. A circuit includes an isolated switch that operates simultaneously to balance battery cells connected in series, and a battery system balances battery modules connected in series, the battery module including battery cells connected in series. The battery cells and modules can be balanced by hierarchical balancing of modules of the battery pack and component cells of the modules.

Abstract: A battery system monitors the status of a battery and ensures safe conditions under a range of events adversely affecting the safety of the battery cells, the battery pack or enclosure, or a vehicle housing the battery. In response to the safety event, the battery system provides one or more responses to secure the battery, disconnect the battery, extinguish a fire, or maintain a safe temperature. Upon detecting the safety event, the a controller activates the safety device accordingly to ensure safe conditions.

Abstract: One or more buttons, located either on a battery pack or on an electronic device powered by the battery pack, that allow the user to charge the battery of a portable device faster than normal. Electronic circuitry is provided for activating the charge mode choices.

Abstract: A storage voltage of a battery pack is controlled with control electronics. The storage voltage of a battery pack is sensed, and a discharge mechanism is triggered if the storage voltage is within a predetermined range of voltage, to thereby adjust the storage voltage of the battery pack to below the predetermined range of voltage, or if the storage voltage is at or above a predetermined voltage, to thereby adjust the storage voltage of the battery pack to below the predetermined voltage. Control electronics sense a storage voltage of a battery pack and trigger a discharge mechanism if the storage voltage is within a predetermined range of voltage, to thereby adjust the storage voltage of the battery pack to below the predetermined range of voltage, or if the storage voltage is at or above a predetermined voltage, to thereby adjust the storage voltage of the battery pack to below the predetermined voltage. The control electronics are coupled to an electronic device and a battery pack.

Abstract: A battery comprises a first terminal in electrical communication with a first electrode of the battery, a second terminal in electrical communication with a second electrode of the battery, a battery can electrically insulated from the first terminal, and at least one current interrupt device in electrical communication with the battery can. The battery can includes a cell casing and a lid which are in electrical communication with each other. At least a portion of the battery can is at least a component of the second terminal, or is electrically connected to the second terminal. The current interrupt device includes a first conductive plate in electrical communication with the second electrode, and a second conductive plate in electrical communication with the first conductive plate.

Abstract: A low pressure current interrupt device (CID) activates at a minimal threshold internal gauge pressure in a range of, for example, between about 4 kg/cm2 and about 9 kg/cm2. Preferably, the CID includes a first conductive plate and a second conductive plate in electrical communication with the first conductive plate, the electrical communication between the first and the second conductive plates being interrupted at the minimal threshold internal gauge pressure. More preferably, the first conductive plate includes a frustum having a first end and a second end, a base extending radially from a perimeter of the first end of the frustum, and an essentially planar cap sealing the second end of the frustum. The first end has a broader diameter than the second end. More preferably, the second conductive plate is in electrical contact with the essentially planar cap through a weld. A battery, preferably a lithium-ion battery, comprises a CID as described above.