Abstract: A containment system for a rechargeable energy storage device (RESS) is described includes an enclosure having a first compartment adjoining a second compartment. The first compartment is arranged to house a plurality of power electronics devices, and the second compartment is arranged to house a plurality of battery cells. The second compartment includes a tub that defines a bottom portion, and a floor plate. The tub includes opposed end walls and opposed sidewalls. A top plate is arranged overtop of the first compartment and the second compartment. A first one of the end walls and the top plate define a first slot between the first compartment and the second compartment. A first removable panel is arranged to enclose the first compartment. The plurality of battery cells connect to the plurality of power electronics devices via a high-voltage DC power bus that is arranged to pass through the first slot.

Abstract: A structural battery pack includes a bottom cover, a bottom cell carrier, multiple battery cells, a cooling ribbon, a top cell carrier, and a top cover. The bottom cover has a rectangular shape that defines a longitudinal direction and a lateral direction. The bottom cell carrier is coupled to the bottom cover, and defines multiple bottom holders. The bottom holders are arranged in a hexagon pattern that defines multiple rows in the longitudinal direction and multiple columns in the lateral direction. The top cell carrier is coupled to the top cover, defines multiple top holders, and includes an interconnect board that interconnects the battery cells. The top holders are arranged in the hexagon pattern. The battery cells are installed in the bottom cell carrier and the top cell carrier. Each battery cell has a cylindrical shape. The cooling ribbon is installed between the battery cells along the rows.

Abstract: A composite cover includes a generally rectangular main portion having four main portion edges about a perimeter of the main portion and having opposing top and bottom surfaces defining respective upward and downward directions, and four generally rectangular side portions each contiguous with and extending downward from a respective one of the main portion edges. The main portion and the four side portions generally enclose an interior space and are made of a sandwich structure comprising an interior layer of continuous fiber reinforcements and resin and an exterior layer of metallic foil bonded to the interior layer. A method of manufacturing the cover, having a desired shape generally of a five-walled open box, includes attaching a formed sheet made of metallic foil and having the desired shape onto a shaped composite preform disposed in the desired shape, wherein the shaped composite preform is made of continuous fiber reinforcements and resin.

Abstract: A hybrid material housing for a battery is provided for reducing or minimizing thermal runaway propagation. The housing includes a composite structure that contains the battery and optionally includes a polymeric matrix selected from the group consisting of: epoxy, phenolic resin, polyester, vinyl ester, and combinations thereof and a reinforcing material selected from the group consisting of: glass fibers, carbon fibers, basalt fibers, aromatic polyamide KEVLAR® fibers, and combinations thereof. A metal layer is disposed along an exterior surface of the composite structure that comprises aluminum, steel, stainless steel, alloys, and combinations thereof. In a first mode, the metal layer contacts the composite structure and in a second mode after exposure to a thermal load of greater than or equal to about 500° C., the metal layer at least partially delaminates from the exterior surface and forms insulating air gaps to define a thermal barrier.

Abstract: Disclosed herein is a battery module comprising a plurality of battery cells encased in an outer shell. The outer shell has disposed on an inner surface a flame retardant layer that comprises expandable graphite. The expandable graphite is operative to expand during an thermal event that results in an increase in battery module temperature. Disclosed herein too is a method comprising disposing in a battery module a flame retardant layer; where the battery module comprises a plurality of battery cells encased in an outer shell. The outer shell has disposed on an inner surface a flame retardant layer that comprises expandable graphite. The expandable graphite is operative to expand during an thermal event that results in an increase in battery module temperature.

Abstract: The present disclosure relates to composite battery covers including one or more integral vent members configured to release pressure. An example composite battery cover includes a continuous sheet having a first stiffness and one or more vent members defined in the continuous sheet. Each of the one or more vent members may include a first area having a second stiffness and/or a second area having a third stiffness. The second stiffness may be different from the first stiffness. The third stiffness may be different from the second stiffness and/or the first stiffness. The stiffness and strength of the continuous sheet and/or one or more vent members may be controlled by variable thicknesses and/or fiber loadings.