Abstract: An electromagnetic switch including a first stationary electric contact, a second stationary electric contact, a mechanical contact, and a moveable contact. The electromagnetic switch is configured for reciprocal motion of the moveable contact into and out of contact with the first stationary electric contact and the second stationary electric contact, wherein the moveable contact remains in contact with the mechanical contact (e.g., a non-conducting contact) throughout the reciprocal motion. In various embodiments, the moveable contact is configured so that at the end of the reciprocal motion three contact points occur, and a triangle defined by the three contact points encloses a center of force of the reciprocal motion.

Abstract: An apparatus and method for identifying a presence of a short circuit in a battery pack. A fault-detection apparatus for a charging system that rapidly charges a collection of interconnected lithium ion battery cells, the safety system includes a data-acquisition system for receiving a set of data parameters from the collection while the charging system is actively charging the collection; a monitoring system evaluating the set of data parameters to identify a set of anomalous conditions; and a controller comparing the set of anomalous conditions against a set of predetermined profiles indicative of an internal short in one or more cells of the collection, the controller establishing an internal-short state for the collection when the comparing has a predetermined relationship to the set of predetermined profiles.

Abstract: An electromagnetic switch including a first stationary electric contact, a second stationary electric contact, a mechanical contact, and a moveable contact. The electromagnetic switch is configured for reciprocal motion of the moveable contact into and out of contact with the first stationary electric contact and the second stationary electric contact, wherein the moveable contact remains in contact with the mechanical contact (e.g., a non-conducting contact) throughout the reciprocal motion. In various embodiments, the moveable contact is configured so that at the end of the reciprocal motion three contact points occur, and a triangle defined by the three contact points encloses a center of force of the reciprocal motion.

Abstract: An electromagnetic switch includes: at least two stationary electric contacts; and a moveable contact, wherein the electromagnetic switch is configured for reciprocal motion of the moveable contact into and out of contact with the stationary electric contacts, wherein the moveable contact is configured so that at least three contact points occur in the reciprocal motion, and so that a triangle defined by the at least three contact points encloses a center of force of the movement.

Abstract: A vortex separator includes: a housing having a cylindrical chamber therein; an inlet through a mantle of the cylindrical chamber, the inlet positioned at a proximal end of the housing; a pipe that enters the housing at the proximal end and extends axially through the cylindrical chamber toward a distal end of the housing which is closed; an outlet through the mantle, the outlet positioned at the distal end; and a catch basin at the outlet.

Abstract: A battery cell design is disclosed that provides a predictable pathway through a portion of the cell (e.g., the cell cap assembly) for the efficient release of the thermal energy that occurs during thermal runaway, thereby reducing the chances of a rupture in an undesirable location. Furthermore the disclosed design maintains the functionality of the cell cap as the positive terminal of the cell, thereby having minimal impact on the manufacturability of the cell as well as its use in a variety of applications.

Abstract: An apparatus and method for identifying a presence of a short circuit in a battery pack. A fault-detection apparatus for a charging system that rapidly charges a collection of interconnected lithium ion battery cells, the safety system includes a data-acquisition system for receiving a set of data parameters from the collection while the charging system is actively charging the collection; a monitoring system evaluating the set of data parameters to identify a set of anomalous conditions; and a controller comparing the set of anomalous conditions against a set of predetermined profiles indicative of an internal short in one or more cells of the collection, the controller establishing an internal-short state for the collection when the comparing has a predetermined relationship to the set of predetermined profiles.

Abstract: A method includes: assembling a thermal-exchange tube in a module housing for an energy storage pack; assembling cells in the module housing, wherein the thermal-exchange tube runs between rows of the cells; applying an adhesive that affixes the cells and the thermal-exchange tube to the module housing; curing a first portion of the adhesive by radiation, wherein a second portion of the adhesive is shielded from the radiation by the cells or the thermal-exchange tube; and curing at least the second portion of the adhesive by a chemical cure mechanism.

Abstract: A vortex separator includes: a housing having a cylindrical chamber therein; an inlet through a mantle of the cylindrical chamber, the inlet positioned at a proximal end of the housing; a pipe that enters the housing at the proximal end and extends axially through the cylindrical chamber toward a distal end of the housing which is closed; an outlet through the mantle, the outlet positioned at the distal end; and a catch basin at the outlet.

Abstract: An apparatus and method for identifying a presence of a short circuit in a battery pack. A fault-detection apparatus for a charging system that rapidly charges a collection of interconnected lithium ion battery cells, the safety system includes a data-acquisition system for receiving a set of data parameters from the collection while the charging system is actively charging the collection; a monitoring system evaluating the set of data parameters to identify a set of anomalous conditions; and a controller comparing the set of anomalous conditions against a set of predetermined profiles indicative of an internal short in one or more cells of the collection, the controller establishing an internal-short state for the collection when the comparing has a predetermined relationship to the set of predetermined profiles.

Abstract: A method for charging at least one lithium ion cell the method includes: (a) applying, to the lithium ion cell, a constant first stage charging current until a first stage charging voltage is about equal to a first stage complete voltage less than a maximum cell voltage, the constant first stage charging current greater than about 1C; and thereafter (b) applying multiple constant second stage charging currents to the lithium ion cell at different current levels, wherein the constant second stage charging currents are applied based on accessing a lookup table that relates at least current, temperature and open source voltage to each other; and thereafter (c) applying, to the lithium ion cell, a constant third stage charging voltage about equal to a complete voltage from the multiple constant second stage charging currents.

Abstract: A computer-implemented method to respond to an exceptional charge event including an overdischarge in an energy storage system having a plurality of series-connected battery elements. The method includes monitoring, using the microprocessor, the energy storage system for a charge imbalance using a first detection modality; initiating a reduction of said charge imbalance using a first response modality; monitoring, using the microprocessor, the energy storage system for the overdischarge of a particular one battery element of the plurality of battery elements using a second detection modality different from said first detection modality; and initiating a response to said exceptional charge event using a second response modality different from said first response modality, said response decreasing a risk associated with said overdischarge.

Abstract: A battery cell design is disclosed that provides a predictable pathway through a portion of the cell (e.g., the cell cap assembly) for the efficient release of the thermal energy that occurs during thermal runaway, thereby reducing the chances of a rupture in an undesirable location. Furthermore the disclosed design maintains the functionality of the cell cap as the positive terminal of the cell, thereby having minimal impact on the manufacturability of the cell as well as its use in a variety of applications.

Abstract: 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.

Abstract: A battery cell charger for rapidly charging a lithium ion battery cell (or string of series-parallel connected cells) having a maximum battery cell voltage the battery cell charging system including: a circuit for charging the battery cell using an adjustable voltage charging-profile to apply a charging voltage and a charging current to the battery cell wherein the adjustable voltage charging-profile includes: a first charging stage with a constant first stage charging current and an increasing battery cell voltage with the first stage charging current provided until the first stage charging voltage is about equal to a first stage complete voltage less than the maximum battery cell voltage; one or more intermediate charging stages, each intermediate stage selected from the group consisting of one or more of an intermediate constant voltage stage that provides a decreasing charging current, an intermediate constant current stage that produces an increasing battery cell voltage, and combinations thereof; and a

Abstract: A method includes: assembling a thermal-exchange tube in a module housing for an energy storage pack; assembling cells in the module housing, wherein the thermal-exchange tube runs between rows of the cells; applying an adhesive that affixes the cells and the thermal-exchange tube to the module housing; curing a first portion of the adhesive by radiation, wherein a second portion of the adhesive is shielded from the radiation by the cells or the thermal-exchange tube; and curing at least the second portion of the adhesive by a chemical cure mechanism.

Abstract: A battery cell charger for rapidly charging a lithium ion battery cell (or string of series-parallel connected cells) having a maximum battery cell voltage the battery cell charging system including: a circuit for charging the battery cell using an adjustable voltage charging-profile to apply a charging voltage and a charging current to the battery cell wherein the adjustable voltage charging-profile includes: a first charging stage with a constant first stage charging current and an increasing battery cell voltage with the first stage charging current provided until the first stage charging voltage is about equal to a first stage complete voltage less than the maximum battery cell voltage; one or more intermediate charging stages, each intermediate stage selected from the group consisting of one or more of an intermediate constant voltage stage that provides a decreasing charging current, an intermediate constant current stage that produces an increasing battery cell voltage, and combinations thereof; and a

Abstract: An apparatus and method for identifying a presence of a short circuit in a battery pack. A fault-detection apparatus for a charging system that rapidly charges a collection of interconnected lithium ion battery cells, the safety system includes a data-acquisition system for receiving a set of data parameters from the collection while the charging system is actively charging the collection; a monitoring system evaluating the set of data parameters to identify a set of anomalous conditions; and a controller comparing the set of anomalous conditions against a set of predetermined profiles indicative of an internal short in one or more cells of the collection, the controller establishing an internal-short state for the collection when the comparing has a predetermined relationship to the set of predetermined profiles.

Abstract: A battery cell charger for rapidly charging a lithium ion battery cell (or string of series-parallel connected cells) having a maximum battery cell voltage the battery cell charging system including: a circuit for charging the battery cell using an adjustable voltage charging-profile to apply a charging voltage and a charging current to the battery cell wherein the adjustable voltage charging-profile includes: a first charging stage with a constant first stage charging current and an increasing battery cell voltage with the first stage charging current provided until the first stage charging voltage is about equal to a first stage complete voltage less than the maximum battery cell voltage; one or more intermediate charging stages, each intermediate stage selected from the group consisting of one or more of an intermediate constant voltage stage that provides a decreasing charging current, an intermediate constant current stage that produces an increasing battery cell voltage, and combinations thereof; and a

Abstract: A battery cell charger for rapidly charging a lithium ion battery cell (or string of series-parallel connected cells) having a maximum battery cell voltage the battery cell charging system including: a circuit for charging the battery cell using an adjustable voltage charging-profile to apply a charging voltage and a charging current to the battery cell wherein the adjustable voltage charging-profile includes: a first charging stage with a constant first stage charging current and an increasing battery cell voltage with the first stage charging current provided until the first stage charging voltage is about equal to a first stage complete voltage less than the maximum battery cell voltage; one or more intermediate charging stages, each intermediate stage selected from the group consisting of one or more of an intermediate constant voltage stage that provides a decreasing charging current, an intermediate constant current stage that produces an increasing battery cell voltage, and combinations thereof; and a