Abstract: Battery systems are provided that include a plurality of modules positioned within an enclosed space (e.g., a room, data center or storage system), wherein at least one of the modules includes a plurality of lithium ion cells and thermal insulator(s) positioned between adjacent lithium ion cells, and wherein the battery systems offer a requisite level of safety by scaling the system such that the internally available volume of the enclosed space (measured in liters) is in the range of about 39±5 times and 80±5 times the amp-hour (Ah) capacity of lithium ion cell(s) positioned therewithin, and associated methods for safe deployment of battery systems in enclosed spaces. The relevant lithium ion cell(s) for determination of Ah capacity is/are the lithium ion cell(s) that is/are thermally insulated relative to adjacent lithium ion cell(s).

Abstract: The present disclosure relates to a modular battery system for use in a variety of motive and non-motive applications. The modular battery system further includes at least one module which is configured and dimensioned for receipt of at least one cell. The at least one cell includes a battery cell for providing energy and a supplementary cell for providing ancillary benefits. One aspect of the disclosure incorporates use of supplementary cells in modules for the purposes of adjusting capacity or voltage, while maintaining the desired weight.

Abstract: Lithium ion batteries are provided that include materials that provide advantageous endothermic functionalities contributing to the safety and stability of the batteries. If the temperature of the lithium ion battery rises above a predetermined level, the endothermic materials serve to provide one or more functions to prevent and/or minimize the potential for thermal runaway, e.g., thermal insulation (particularly at high temperatures); (ii) energy absorption; (iii) venting of gases produced, (iv) raising total pressure within the battery structure; (v) removal of absorbed heat from the battery system via venting of gases produced during the endothermic reaction(s) associated with the endothermic materials, and/or (vi) dilution of toxic gases (if present) and their safe expulsion from the battery system. Multi-core rechargeable electrochemical assemblies are also provided that include a plurality of jelly rolls, a negative current collector, a positive current collector, and a metal case.

Abstract: Battery systems are provided that include a plurality of modules positioned within an enclosed space (e.g., a room, data center or storage system), wherein at least one of the modules includes a plurality of lithium ion cells and thermal insulator(s) positioned between adjacent lithium ion cells, and wherein the battery systems offer a requisite level of safety by scaling the system such that the internally available volume of the enclosed space (measured in liters) is in the range of about 39±5 times and 80±5 times the amp-hour (Ah) capacity of lithium ion cell(s) positioned therewithin, and associated methods for safe deployment of battery systems in enclosed spaces. The relevant lithium ion cell(s) for determination of Ah capacity is/are the lithium ion cell(s) that is/are thermally insulated relative to adjacent lithium ion cell(s).

Abstract: The present disclosure provides for advantageous electrolyte filling systems/methods utilizing predetermined pressure/flow cycles. The disclosed electrolyte filling system enables filling of at least one jelly roll assembly under vacuum. The disclosed electrolyte filling system is capable of simultaneously filling at least two multi-core lithium ion batteries. The disclosed multi-core lithium ion batteries include a plurality of jelly roll assemblies positioned within cavities, which are further positioned within a sealed enclosure. The disclosed jelly roll assemblies are electrically connected to at least one bus bar. The disclosed bus bars include at least one flexible connective structure to electrically connect to a sealed enclosure.

Abstract: Materials and novel methods for producing carbon anodes for Li-ion batteries are described. These materials use natural flake graphite that has been processed to improve physical properties but retains residual impurities including silicates and other silicon containing minerals that are difficult to eliminate economically. For the purposes of battery anode material production, further purification is required and traditionally uses hydrofluoric acid, adding significant cost and environmental management requirements. Alternate novel processes result in less costly and more environmentally friendly methods when compared against the standard acid purification with hydrofluoric acid. Methods for direct graphitization of unpurified spheroidized graphite material that includes a carbonaceous coating in production of a lithium ion battery anode are provided. Materials generated using these methods may be blended with artificial graphite and particulate Silicon or SiOx materials for enhanced properties.

Abstract: A multi-core lithium ion battery includes a sealed enclosure and a support member disposed within the sealed enclosure. The sealed enclosure may be fabricated with a clamshell configuration. The sealed enclosure may further include at least two support members housed within individual compartments, separated by shared wall(s). The support member(s) includes a plurality of cavities and a plurality of lithium ion core members which are disposed within the plurality of cavities. The battery may further include a plurality of cavity liners, each of which is positioned between a corresponding one of the lithium ion core members and a surface of a corresponding one of the cavities. The hermetically sealed enclosure may be formed using a clamshell configuration. Structures may be included in proximity to or in contact with the lithium ion core members to control gas/fluid flow therefrom.

Abstract: Casings for lithium ion batteries are provided that include a container or assembly that defines a base, side walls and a top or lid, and a vent structure associated with the container or assembly. A flame arrestor may be positioned in proximity to the vent structure. The lithium ion battery may also include a pressure disconnect device associated with the casing. The pressure disconnect device may include a deflectable dome-based activation mechanism, and the deflectable dome-based activation mechanism may be configured and dimensioned to prevent burn through, e.g., by increasing the mass of the dome-based activation mechanism, adding material (e.g., foil) to the dome-based activation mechanism, and combinations thereof. Burn through may also be avoided, at least in part, based on the speed at which the dome-based activation mechanism responds at a target trigger pressure.

Abstract: Lithium ion batteries are provided that include materials that provide advantageous endothermic functionalities contributing to the safety and stability of the batteries. The endothermic materials may include a ceramic matrix incorporating an inorganic gas-generating endothermic material. If the temperature of the lithium ion battery rises above a predetermined level, the endothermic materials serve to provide one or more functions to prevent and/or minimize the potential for thermal runaway, e.g.

Abstract: A multi-core lithium ion battery includes a sealed enclosure and a support member disposed within the sealed enclosure. The sealed enclosure may further include at least two support members housed within individual compartments, separated by shared wall(s). The support member(s) includes a plurality of cavities and a plurality of lithium ion core members which are disposed within the plurality of cavities. The battery may further include a plurality of cavity liners, each of which is positioned between a corresponding one of the lithium ion core members and a surface of a corresponding one of the cavities. The hermetically sealed enclosure may be formed using a clamshell configuration. Structures may be included in proximity to or in contact with the lithium ion core members to control gas/fluid flow therefrom.

Abstract: A multi-core lithium ion battery includes a sealed enclosure and a support member disposed within the sealed enclosure. The support member includes a plurality of cavities and a plurality of lithium ion core members which are disposed the plurality of cavities. The battery further includes a plurality of cavity liners, each of which is positioned between a corresponding one of the lithium ion core members and a surface of a corresponding one of the cavities.

Abstract: A multi-core lithium ion battery includes a sealed enclosure and a support member disposed within the sealed enclosure. The sealed enclosure may further include at least two support members housed within individual compartments, separated by shared wall(s). The support member(s) includes a plurality of cavities and a plurality of lithium ion core members which are disposed within the plurality of cavities. The battery may further include a plurality of cavity liners, each of which is positioned between a corresponding one of the lithium ion core members and a surface of a corresponding one of the cavities. The hermetically sealed enclosure may be formed using a clamshell configuration. Structures may be included in proximity to or in contact with the lithium ion core members to control gas/fluid flow therefrom. The sealed enclosure may further include temperature altering mechanisms for increasing cold cranking capabilities.

Abstract: Casings for electrochemical elements are provided that include a container or assembly that defines a base plate, sidewalls and a top plate or lid, an overcharge electrical disconnect feature, and a vent structure associated with the container or assembly. A flame arrestor may be positioned in proximity to the vent structure. The overcharge electrical disconnect feature electrically separates the electrochemical elements from the casing when the internal pressure of the casing reaches a predetermined threshold. The lithium ion battery may also include a pressure disconnect device associated with the casing. The pressure disconnect device may include a deflectable dome-based activation mechanism, and the deflectable dome-based activation mechanism may be configured and dimensioned to prevent burn through.

Abstract: Lithium ion batteries are provided that include a plurality of electrochemical units positioned within a container or assembly. A multi-layered bus bar is provided to establish electrical connection with the anode and cathode of the electrochemical units. Based on the design of the bus bar, a desired voltage and capacity may be delivered by the battery without redesign or redeployment of the electrochemical units within the container or assembly. A plurality of bus bars may be interchangeably introduced to the container/assembly to yield lithium ion batteries that deliver differing voltage and/or capacity.

Abstract: A multi-core lithium ion battery includes a sealed enclosure and a support member disposed within the sealed enclosure. The support member includes a plurality of cavities and a plurality of lithium ion core members which are disposed the plurality of cavities. The battery further includes a plurality of cavity liners, each of which is positioned between a corresponding one of the lithium ion core members and a surface of a corresponding one of the cavities.

Abstract: Casings for lithium ion batteries are provided that include a container or assembly that defines a base, side walls and a top or lid, and a vent structure associated with the container or assembly. A flame arrestor may be positioned in proximity to the vent structure. The lithium ion battery may also include a pressure disconnect device associated with the casing. The pressure disconnect device may include a deflectable dome-based activation mechanism, and the deflectable dome-based activation mechanism may be configured and dimensioned to prevent burn through, e.g., by increasing the mass of the dome-based activation mechanism, adding material (e.g., foil) to the dome-based activation mechanism, and combinations thereof. Burn through may also be avoided, at least in part, based on the speed at which the dome-based activation mechanism responds at a target trigger pressure.

Abstract: A multi-core lithium ion battery includes a sealed enclosure and a support member disposed within the sealed enclosure. The sealed enclosure may be fabricated with a clamshell configuration. The sealed enclosure may further include at least two support members housed within individual compartments, separated by shared wall(s). The support member(s) includes a plurality of cavities and a plurality of lithium ion core members which are disposed within the plurality of cavities. The battery may further include a plurality of cavity liners, each of which is positioned between a corresponding one of the lithium ion core members and a surface of a corresponding one of the cavities. The hermetically sealed enclosure may be formed using a clamshell configuration. Structures may be included in proximity to or in contact with the lithium ion core members to control gas/fluid flow therefrom.

Abstract: A multi-core lithium ion battery includes a sealed enclosure and a support member disposed within the sealed enclosure. The sealed enclosure may further include at least two support members housed within individual compartments, separated by shared wall(s). The support member(s) includes a plurality of cavities and a plurality of lithium ion core members which are disposed within the plurality of cavities. The battery may further include a plurality of cavity liners, each of which is positioned between a corresponding one of the lithium ion core members and a surface of a corresponding one of the cavities. The hermetically sealed enclosure may be formed using a clamshell configuration. Structures may be included in proximity to or in contact with the lithium ion core members to control gas/fluid flow therefrom.

Abstract: A multi-core lithium ion battery includes a sealed enclosure and a support member disposed within the sealed enclosure. The support member includes a plurality of cavities and a plurality of lithium ion core members which are disposed the plurality of cavities. The battery further includes a plurality of cavity liners, each of which is positioned between a corresponding one of the lithium ion core members and a surface of a corresponding one of the cavities.

Abstract: A multi-core lithium ion battery includes a sealed enclosure and a support member disposed within the sealed enclosure. The support member includes a plurality of cavities and a plurality of lithium ion core members which are disposed the plurality of cavities. The battery further includes a plurality of cavity liners, each of which is positioned between a corresponding one of the lithium ion core members and a surface of a corresponding one of the cavities.