Abstract: There is described a battery module comprising: a cell enclosure for housing a plurality of battery cells; and a cooling assembly. The cooling assembly comprises a cooling channel extending from an aperture in a first side of the battery module to an aperture in a second side of the battery module. The cooling channel is positioned such that heat generated within the cell enclosure may be transferred to a cooling 5 fluid flowing, via the cooling channel, from the first side of the battery module to the second side of the battery module. There is also described a battery module stack comprising multiple such battery modules. The battery modules are arranged in a stacked formation such that the cooling channel of at least one battery module is aligned with the cooling channel of at least one adjacent battery module.

Abstract: A battery module includes an enclosure that has at least one heat sink. Within the module is a stack assembly composed of a series of cell carrier assemblies connected together. The cell carrier assemblies each include a cell carrier that has a first spring that is biased against the heat sink. Each of the cell carrier assemblies also includes a battery cell and a heat conductive sheet that is thermally coupled to the battery cell. The heat conductive sheet is positioned to be pressed against the heat sink by the first spring to facilitate a good thermal connection between the sheet and the heat sink. Heat is accordingly conducted away from the battery cell, along the heat conductive sheet, to the heat sink.

Abstract: Present embodiments disclosure discloses a battery module, which includes a plurality of battery cells, a busbar, a cover member, an insulator member positioned between the plurality of battery cells, and a casing element enclosing all the above. The cover member positioned above the busbar. The cover member includes an elongated body defining a first major surface and a second major surface, where the second major surface is defined with a plurality of grooves. The cover member also includes a plurality of dimples are defined along at least one of the first major surface and the second major surface. Further, at least one dimple of the plurality of dimples melt and form an aperture when at least one battery cell of the battery module undergoes a thermal runaway, to fluidly connect the first major surface with the plurality of grooves.

Abstract: A system comprising one or more battery modules mounted in a rack assembly has a structure which defines a cooling air pathway for flowing cooling air across the side and/or bottom of each battery module thereby cooling the battery module, or alternatively, across the energy calls in the battery module. Further, the system has a structure which defines a thermal runaway gas pathway for flowing thermal runaway gases from a battery module out of the system. The system structure is configured to ensure that the cooling air pathway and thermal runaway gas pathway are physically separated, thereby minimizing the risk of the thermal runaway gas substantially mixing with cooling air thereby potentially resulting in a spontaneous ignition and an explosion.

Abstract: There is provided a backplane assembly with a power substructure and a cooling substructure. Battery modules may be engaged with the backplane assembly. When engaged, power connectors in the power substructure engage with corresponding power connectors on the battery modules. A cooling fluid moving through the cooling substructure is directed toward the battery modules so as to cool the battery modules during operation. The backplane assembly may additionally include an exhaust substructure. Gases vented by the battery modules move through the exhaust substructure and are directed away from the backplane assembly.

Abstract: A battery module includes an enclosure that has at least one heat sink. Within the module is a stack assembly composed of a series of cell carrier assemblies connected together. The cell carrier assemblies each include a cell carrier that has a first spring that is biased against the heat sink. Each of the cell carrier assemblies also includes a battery cell and a heat conductive sheet that is thermally coupled to the battery cell. The heat conductive sheet is positioned to be pressed against the heat sink by the first spring to facilitate a good thermal connection between the sheet and the heat sink. Heat is accordingly conducted away from the battery cell, along the heat conductive sheet, to the heat sink.

Abstract: An optically communicative battery management system includes a pack controller and one or more module controllers optically coupled to the pack controller. The module controllers may themselves be optically coupled together in series, and communication from an upstream module controller may be relayed through one or more downstream controllers en route to the pack controller. The pack controller may also send an optical signal that is used by the pack controller to determine whether any one or more of the battery modules is experiencing a safety fault, and the communication channel used to transmit that optical signal may, absent any safety faults, be used to multiplex message data to the module controllers.

Abstract: A cell carrier includes a phase change material compartment containing phase change material. The phase change material has a phase transition temperature between a normal operating temperature of the battery cell and a self-heating point of the battery cell, and the phase change material transitions from a solid state to a liquid state or from a liquid state to a gaseous state when heated to the phase transition temperature.

Abstract: A method and system for iteratively determining state of charge (SOC) of a battery cell (“selected cell”) using a controller. For each of the iterations, the controller determines determine a predicted SOC of the selected cell; determines a predicted error covariance of the predicted SOC; and updates the predicted SOC and the predicted error covariance for use in subsequent iterations of the method. The updated SOC is treated as the SOC of the selected cell for that iteration of the method. Cell voltage used to determine the updated SOC may be low-pass filtered prior to its use. When the selected cell is one of multiple cells in a battery pack, the selected cell may be selected to have the lowest SEV of the cells in the pack. The error covariance may also vary directly with pack current magnitude to model inaccuracies that generally directly vary with current flow.

Abstract: The present disclosure is directed at a cell carrier, a stack that includes multiple cell carriers, and a method for assembling the stack. The cell carrier has a rigid backing and bus bar supports that are rigidly mounted to the rigid backing The bus bar supports have sockets positioned to receive fasteners for securing bus bars to the bus bar supports. A battery cell that has electrodes in the form of pliable tabs can be secured to the cell carrier by, for example, adhering the cell body to the rigid backing The cell tabs are secured between the bus bars and the bus bar supports when bus bars are fastened to the bus bar supports, and the rigidly mounted supports help prevent relative motion between the cell body and tabs. This helps prevent the cell tabs from ripping or tearing when the battery cell is subjected to vibrations during use.

Abstract: The present disclosure is directed at a cell carrier, a stack that includes multiple cell carriers, and a method for assembling the stack. The cell carrier has a rigid backing and bus bar supports that are rigidly mounted to the rigid backing The bus bar supports have sockets positioned to receive fasteners for securing bus bars to the bus bar supports. A battery cell that has electrodes in the form of pliable tabs can be secured to the cell carrier by, for example, adhering the cell body to the rigid backing The cell tabs are secured between the bus bars and the bus bar supports when bus bars are fastened to the bus bar supports, and the rigidly mounted supports help prevent relative motion between the cell body and tabs. This helps prevent the cell tabs from ripping or tearing when the battery cell is subjected to vibrations during use.