Abstract: Provided are battery packs and interface modules for electrically interconnecting electrochemical cells in the packs and for providing heat distribution with the packs. An interface module interfaces one side of all electrochemical cells in a battery pack. The interface module may have a substantially planar shape such that the space occupied by the module in the battery pack is minimal. Most, if not all, conductive components of the interface module may be formed from the same sheet of metal. In some embodiments, the interface module includes multiple bus bars such that each bus bar interconnects two or more terminals of different electrochemical cells in the battery pack. Each bus bar may have a separate voltage sense lead extending from the bus bar to a connecting portion. The bus bars may be flexibly supported within the module. The interface module may also include multiple thermistors disposed on different bus bars.

Abstract: Provided are battery packs and interface modules for electrically interconnecting electrochemical cells in the packs and for providing heat distribution with the packs. An interface module interfaces one side of all electrochemical cells in a battery pack. The interface module may have a substantially planar shape such that the space occupied by the module in the battery pack is minimal. Most, if not all, conductive components of the interface module may be formed from the same sheet of metal. In some embodiments, the interface module includes multiple bus bars such that each bus bar interconnects two or more terminals of different electrochemical cells in the battery pack. Each bus bar may have a separate voltage sense lead extending from the bus bar to a connecting portion. The bus bars may be flexibly supported within the module. The interface module may also include multiple thermistors disposed on different bus bars.

Abstract: Provided are battery packs and interface modules for electrically interconnecting electrochemical cells in the packs and for providing heat distribution with the packs. An interface module interfaces one side of all electrochemical cells in a battery pack. The interface module may have a substantially planar shape such that the space occupied by the module in the battery pack is minimal. Most, if not all, conductive components of the interface module may be formed from the same sheet of metal. In some embodiments, the interface module includes multiple bus bars such that each bus bar interconnects two or more terminals of different electrochemical cells in the battery pack. Each bus bar may have a separate voltage sense lead extending from the bus bar to a connecting portion. The bus bars may be flexibly supported within the module. The interface module may also include multiple thermistors disposed on different bus bars.

Abstract: Provided are battery packs and interface modules for electrically interconnecting electrochemical cells in the packs and for providing heat distribution with the packs. An interface module interfaces one side of all electrochemical cells in a battery pack. The interface module may have a substantially planar shape such that the space occupied by the module in the battery pack is minimal. Most, if not all, conductive components of the interface module may be formed from the same sheet of metal. In some embodiments, the interface module includes multiple bus bars such that each bus bar interconnects two or more terminals of different electrochemical cells in the battery pack. Each bus bar may have a separate voltage sense lead extending from the bus bar to a connecting portion. The bus bars may be flexibly supported within the module. The interface module may also include multiple thermistors disposed on different bus bars.

Abstract: A battery assembly including a plurality of battery cells and at least one frame having a support feature formed thereon is disclosed. The support feature supports electrically conductive tabs of the battery cells and militates against damage to the battery assembly during a joining of one of the electrically conductive tabs with another one of the electrically conductive tabs of an adjacent battery cell or during a joining of the electrically conductive tabs of adjacent battery cells with a connector.

Abstract: Provided are battery packs and interface modules for electrically interconnecting electrochemical cells in the packs and for providing heat distribution with the packs. An interface module interfaces one side of all electrochemical cells in a battery pack. The interface module may have a substantially planar shape such that the space occupied by the module in the battery pack is minimal. Most, if not all, conductive components of the interface module may be formed from the same sheet of metal. In some embodiments, the interface module includes multiple bus bars such that each bus bar interconnects two or more terminals of different electrochemical cells in the battery pack. Each bus bar may have a separate voltage sense lead extending from the bus bar to a connecting portion. The bus bars may be flexibly supported within the module. The interface module may also include multiple thermistors disposed on different bus bars.

Abstract: A component for reducing the likelihood of ice-related blockage in a fuel cell and methods for starting a fuel cell system. In one embodiment, the component is a separate insert configured with a sharp leading edge such that water droplets present in a reactant fluid that pass through an orifice in the component are conveyed away from an unstable formation at the edge to a more stable formation in an adjacent part of the component. In one form, the component is sized to fit within a valve inlet that in turn is placed in a humid reactant flowpath. In this way, when the fuel cell is operated in cold conditions—such as those associated with temperatures at or below the freezing point of water—the water droplets do not freeze in the area around the orifice such that ice-related blockage of the flowpath does not occur.

Abstract: A cooling module for a battery pack assembly is disclosed. The cooling module includes a frame having a plurality of legs forming an opening through a central portion of the frame, at least one of the plurality of legs including a slot formed therethrough. A cooling fin is coupled to the frame. The cooling fin includes a corrugated plate interposed between a first plate and a second plate forming a plurality of fluid flow channels between the first plate and the second plate. The cooling modules are disposed in a stack having at least one battery cell disposed between adjacent cooling modules. The battery cell is in heat transfer communication with the cooling fin of at least one cooling module, wherein the cooling fin facilitates a transfer of heat energy between the battery cell and the flow channels formed in the cooling fin.

Abstract: A fixture is configured for holding terminals of a battery in alignment. The fixture includes a first and a second side member. The first and second side members each include a plurality of first and second teeth, respectively. The second side member is movable relative to the first side member between an open position and a closed position. The second side member opposes the first side member such that a number of the first teeth oppose a corresponding number of the second teeth and a slit is defined between each of the adjacent teeth when the fixture is in the open position. Likewise, the second side member opposes the first side member such that the number of the first teeth are staggered from the corresponding number of the second teeth to reduce the slit in size when the fixture is in the closed position.

Abstract: An interconnect device for a battery assembly having a plurality of battery cell assemblies and a thermistor is disclosed. The interconnect device includes a non-conductive frame; a plurality of conductive traces integrally formed with the frame, a busbar in electrical communication with at least one of the conductive traces and disposed adjacent an aperture formed in the frame, wherein the aperture receives a tab of at least one of the battery cell assemblies, and a conductive pad disposed on a lower surface of the frame, the pad in electrical communication with at least one of the conductive traces and adapted to receive a signal from the thermistor.

Abstract: A battery assembly including a plurality of battery cells and at least one frame having a support feature formed thereon is disclosed. The support feature supports electrically conductive tabs of the battery cells and militates against damage to the battery assembly during a joining of one of the electrically conductive tabs with another one of the electrically conductive tabs of an adjacent battery cell or during a joining of the electrically conductive tabs of adjacent battery cells with a connector.

Abstract: A battery assembly including a plurality of battery cells and at least one frame having a support feature formed thereon is disclosed. The support feature supports electrically conductive tabs of the battery cells and militates against damage to the battery assembly during a joining of one of the electrically conductive tabs with another one of the electrically conductive tabs of an adjacent battery cell or during a joining of the electrically conductive tabs of adjacent battery cells with a connector.

Abstract: A component for reducing the likelihood of ice-related blockage in a fuel cell and methods for starting a fuel cell system. In one embodiment, the component is a separate insert configured with a sharp leading edge such that water droplets present in a reactant fluid that pass through an orifice in the component are conveyed away from an unstable formation at the edge to a more stable formation in an adjacent part of the component. In one form, the component is sized to fit within a valve inlet that in turn is placed in a humid reactant flowpath. In this way, when the fuel cell is operated in cold conditions—such as those associated with temperatures at or below the freezing point of water—the water droplets do not freeze in the area around the orifice such that ice-related blockage of the flowpath does not occur.

Abstract: A battery pack is described. One embodiment of the battery pack includes a pair of end frames, the end frames having a top and a bottom and a pair of sides, the end frames having a detent on at least one of the sides of the end frames to receive a clamp; a frame positioned between the pair of end frames, the frame having a top and a bottom and a pair of sides, the frame having a ridge on at least one of the sides of the frame; a plurality of battery cells positioned in the frame and the pair of end frames, the plurality of battery cells electrically connected to each other at the top of the frame; and at least one cooling fin positioned between the battery cells. Methods of repairing battery packs are also described.

Abstract: A battery pack is described. One embodiment of the battery pack includes a pair of end frames, the end frames having a top and a bottom and a pair of sides, the end frames having a detent on at least one of the sides of the end frames to receive a clamp; a frame positioned between the pair of end frames, the frame having a top and a bottom and a pair of sides, the frame having a ridge on at least one of the sides of the frame; a plurality of battery cells positioned in the frame and the pair of end frames, the plurality of battery cells electrically connected to each other at the top of the frame; and at least one cooling fin positioned between the battery cells. Methods of repairing battery packs are also described.

Abstract: A battery assembly including a plurality of battery cells and at least one frame having a support feature formed thereon is disclosed. The support feature supports electrically conductive tabs of the battery cells and militates against damage to the battery assembly during a joining of one of the electrically conductive tabs with another one of the electrically conductive tabs of an adjacent battery cell or during a joining of the electrically conductive tabs of adjacent battery cells with a connector.

Abstract: A cooling module for a battery pack assembly is disclosed. The cooling module includes a frame having a plurality of legs forming an opening through a central portion of the frame, at least one of the plurality of legs including a slot formed therethrough. A cooling fin is coupled to the frame. The cooling fin includes a corrugated plate interposed between a first plate and a second plate forming a plurality of fluid flow channels between the first plate and the second plate. The cooling modules are disposed in a stack having at least one battery cell disposed between adjacent cooling modules. The battery cell is in heat transfer communication with the cooling fin of at least one cooling module, wherein the cooling fin facilitates a transfer of heat energy between the battery cell and the flow channels formed in the cooling fin.

Abstract: An interconnect device for a battery assembly having a plurality of battery cell assemblies and a thermistor is disclosed. The interconnect device includes a non-conductive frame; a plurality of conductive traces integrally formed with the frame, a busbar in electrical communication with at least one of the conductive traces and disposed adjacent an aperture formed in the frame, wherein the aperture receives a tab of at least one of the battery cell assemblies, and a conductive pad disposed on a lower surface of the frame, the pad in electrical communication with at least one of the conductive traces and adapted to receive a signal from the thermistor.

Abstract: A fixture is configured for holding terminals of a battery in alignment. The fixture includes a first and a second side member. The first and second side members each include a plurality of first and second teeth, respectively. The second side member is movable relative to the first side member between an open position and a closed position. The second side member opposes the first side member such that a number of the first teeth oppose a corresponding number of the second teeth and a slit is defined between each of the adjacent teeth when the fixture is in the open position. Likewise, the second side member opposes the first side member such that the number of the first teeth are staggered from the corresponding number of the second teeth to reduce the slit in size when the fixture is in the closed position.