Abstract: One embodiment includes a method that includes monitoring a battery state of charge circuit that is coupled to a vehicle battery, calculating an averaged value of the state of charge over a time period, charging the vehicle battery by powering a generator with a fuel burning engine that powered on and powered off according to one of a first operational mode and a second operational mode, wherein in the first operational mode the engine is powered on when the battery state of charge drops below a first state of charge and continues until the averaged value of the state of charge increases to a first preprogrammed value.

Abstract: A vehicle seat mounting assembly is provided in which the seat mounts are attached to body cross-members that are, in turn, mechanically coupled to battery pack cross-members contained within a battery pack enclosure mounted under the vehicle.

Abstract: A passive sound pressure level (SPL) limiter is provided that can be used with audio sources of varying drive levels and headsets, earbuds, etc. of varying sensitivity. The SPL limiter includes a control circuit that includes a rectifier and, in most configurations, a step-up transformer. The SPL limiter also includes a limiting circuit that utilizes a transistor to shunt current from the audio source in proportion to a control signal output by the control circuit. The control circuit may further include a low pass filter, for example an RC filter, and one or more fast limit diode paths. The limiting circuit may further include a feedback network to increase the linear behavior of the limiting circuit.

Abstract: A dual mode, thermal management system for use in a vehicle is provided. At a minimum, the system includes a first coolant loop in thermal communication with a battery system, a second coolant loop in thermal communication with at least one drive train component (e.g., electric motor, power electronics, inverter), and a dual mode valve system that provides means for selecting between a first mode where the two coolant loops operate in parallel, and a second mode where the two coolant loops operate in series.

Abstract: A method for detecting and responding to a battery thermal event within a sealed battery pack is provided. The method includes the steps of monitoring and characterizing the pressure within the battery pack over time, where identifying a battery thermal event is based on the pressure data fitting a specific curve shape, and performing a preset response when a battery thermal event is identified. The method may additionally monitor for a secondary effect associated with the battery thermal event.

Abstract: A method and apparatus is provided in which a pre-formed sleeve or pre-formed secondary can comprised of one or more layers of a high yield strength material is positioned around the pre-formed battery case, the pre-formed sleeve/secondary can inhibiting the flow of hot, pressurized gas from within the battery through perforations formed in the battery casing during a thermal runaway event.

Abstract: A system and method for collecting, storing and using the oxygen-rich effluent generated when charging a metal-air battery pack is provided.

Abstract: An apparatus for simplifying battery pack encapsulation is provided. The battery pack includes a pair of complementary housing members with each housing member including a plurality of cell constraints into which the ends of corresponding battery cells are inserted during assembly. One or both housing members also include at least one, and preferably a plurality, of raised encapsulant injection ports. The raised encapsulant injection ports are designed to extend above the surface of the respective housing members and beyond the injected encapsulation material, thus ensuring that the ports remain open after encapsulation material injection.

Abstract: An improved protection system for a battery pack mounted between the passenger cabin floor panel of an electric vehicle and the driving surface is provided, the system utilizing a ballistic shield mounted under the electric vehicle and interposed between the battery pack enclosure and the driving surface, where the ballistic shield is spaced apart from the enclosure bottom panel. A layer of a compressible material may be interposed between the ballistic shield and the battery pack enclosure.

Abstract: A battery pack thermal management system is provided that is comprised of at least one enclosure failure port integrated into at least one wall of a battery pack enclosure, where the enclosure failure port(s) remains closed during normal operation of the battery pack, and opens during a battery pack thermal runaway event, thereby providing a flow path for hot gas generated during the thermal runaway event to be exhausted out of the battery pack enclosure in a controlled fashion.

Abstract: A thermal management system is provided that minimizes the effects of thermal runaway within a battery pack. The system is comprised of a multi-sided, substantially airtight battery pack enclosure configured to hold a plurality of batteries, where at least one side of the battery pack enclosure includes at least one cavity. An inner wall of the enclosure includes a plurality of perforations configured to pass gas from within the enclosure to the cavity within the at least one side member. The system is further comprised of at least one gas exhaust port integrated into an outer wall of the enclosure and configured to pass gas from within the cavity of the enclosure side member to the ambient environment when one or more batteries contained within the battery pack undergo thermal runaway.

Abstract: A battery assembly is provided that includes a layer of intumescent material that coats the sidewall and bottom surface of the cell casing, excluding at least one case contact region.

Abstract: A liquid cooling manifold assembly for use in the thermal management system of a battery pack is provided. The liquid cooling manifold assembly includes a coolant channel portion through which the coolant channels run, and a dual layer thermal interface interposed between the coolant channel portion and the cells of the battery pack. The outer material layer of the dual layer thermal interface is comprised of an electrically non-conductive, high dielectric material that is preferably tear resistant, deformable and has a high tensile strength and a relatively low surface friction. The inner material layer of the dual layer thermal interface is comprised of a highly compressible material.

Abstract: A method for controlling the relative humidity within a battery pack enclosure is provided in which the volume of air within the battery pack is exposed to a volume of desiccant contained within a desiccant enclosure. The system is configured to heat and reactivate the desiccant at predetermined time intervals or when the humidity within the system reaches a preset level, thereby allowing the desiccant to regain its potential for absorbing/adsorbing water vapor.

Abstract: A system for integrating the venting feature of a battery with a means for simultaneously disconnecting the cell from the battery pack, thereby isolating the cell, is provided. The provided battery interconnect system is comprised of a battery, a connector plate for electrically coupling the battery to a battery pack, and an interruptible electrical connector for electrically coupling the connector plate to a battery terminal vent. The vent, defined by scoring on the battery terminal, ruptures when the internal battery pressure exceeds the predefined battery operating range, causing the interruptible electrical connector to break and disrupt electrical continuity between the connector plate and the battery terminal.

Abstract: A method and apparatus for simplifying battery pack encapsulation is provided. The battery pack includes a pair of complementary housing members with each housing member including a plurality of cell constraints into which the ends of corresponding battery cells are inserted during assembly. One or both housing members also include at least one, and preferably a plurality, of raised encapsulant injection ports. The raised encapsulant injection ports are designed to extend above the surface of the respective housing members and beyond the injected encapsulation material, thus ensuring that the ports remain open after encapsulation material injection.

Abstract: An integrated eartip (501) that utilizes a one-piece, rather than a multi-piece, design is provided. The one-piece design is comprised of a first portion that includes at least one, or at least two, sound delivery tubes (513/515) and a second portion that is comprised of a compressible region. The integrated eartip also includes means for releasably attaching the eartip to an earphone in general, and a coupling member (503) in particular, thus allowing the eartip to be replaced as desired. When attached, the sound delivery tube, or tubes, of the integrated eartip are aligned with the acoustic port, or ports, of the earphone/coupling member. The first and second portions of the integrated eartip may exhibit different rigidity and/or compressibility characteristics. The integrated eartip can be fabricated from a single material such as a natural or synthetic elastomer.