Abstract: The present disclosure relates to a battery test system for a vehicle that includes a camera configured to capture an image of a vehicle identification number located on the vehicle, the camera being coupled to a processor which determines characters of the vehicle identification number from the image of the camera and correlates the characters of the vehicle identification number to a vehicle identification number database to receive battery parameters for the vehicle, a battery tester that is removably connected to terminals of a battery of the vehicle and configured to receive battery test results, and a display which conveys information relating to the battery parameters and the battery test results.

Abstract: Disclosed is a battery having a conductive terminal extending beyond a surface of a battery cover, the conductive terminal having an internal portion and an external surface, wherein the internal portion comprises lead and external surface comprises a non-lead conductive material. Further disclosed is a method for producing such a battery.

Abstract: A vent adapter for a lead-acid battery includes a first side configured to mate with a vent port of the lead-acid battery via a first connector having a first geometry; and a second side in fluid communication with the first side and configured to mate with a vent passage of an automobile via a second connector having a second geometry, wherein the first and second geometries have respective shapes that are different from one another.

Abstract: The present disclosure relates to methods by which lead from spent lead-acid batteries may be extracted, purified, and used in the construction of new lead-acid batteries. A method includes: (A) forming a mixture including a carboxylate source and a lead-bearing material; (B) generating a first lead salt precipitate in the mixture as the carboxylate source reacts with the lead-bearing material; (C) increasing the pH of the mixture to dissolve the first lead salt precipitate; (D) isolating a liquid component of the mixture from one or more insoluble components of the mixture; (E) decreasing the pH of the liquid component of the mixture to generate a second lead salt precipitate; and (F) isolating the second lead salt precipitate from the liquid component of the mixture. Thereafter, the isolated lead salt precipitate may be converted to leady oxide for use in the manufacture of new lead-acid batteries.

Abstract: An energy storage system for supporting dual electrical functions of a vehicle includes an energy storage unit having a plurality of energy storage modules connected in series, a plurality of sensing units for sensing state of charges of the plurality of energy storage modules, and a pair of primary voltage terminals. The series connected plurality of energy storage modules is connectable across the pair of primary voltage terminals during a key-on state of the vehicle to supply energy storage power at a first voltage level to support primary electrical functions of the vehicle. The energy storage system is further configured to select a subset of the plurality of energy storage modules during a key-off state of the vehicle to connect across a pair of secondary voltage terminals using a switch network to supply energy storage power at a second voltage level.

Abstract: The present disclosure includes a lithium-ion battery module that has a housing and a plurality of lithium-ion battery cells disposed in the housing. Each of the plurality of lithium-ion battery cells includes a first terminal with a first polarity, a second terminal with a second polarity opposite to the first polarity, an overcharge protection assembly, and a casing electrically coupled to the first terminal such that the casing has the first polarity, where the casing has an electrically conductive material. The lithium-ion battery module also includes a vent of the overcharge protection assembly electrically coupled to the casing and a conductive component of the overcharge protection assembly electrically coupled to the second terminal, and the vent is configured to contact the conductive component to cause a short circuit and to vent a gas from the casing into the housing when a pressure in the casing reaches a threshold value.

Abstract: A module-based framework evaluates designs of advanced start stop systems, particularly 12V advanced start stop systems. The framework separates vehicle and battery analysis and uses a power profile to evaluate different designs of the vehicles and batteries. Particularly, the framework can evaluate different battery solutions and compare performances as a function of drive cycles, motor size, and electrical loads. In addition to modeling, actual batteries are tested for the same power inputs for validating performance differences. This framework identifies performance limiting components for determination of the vehicle system component optimization.

Abstract: The present invention provides a battery control system for controlling a battery pack that is formed by a plurality of battery cells.

Abstract: An automotive battery system that includes a lead-acid battery electrically coupled to a first bus, in which the lead-acid battery supplies electrical power to a starter via the first bus to cold crank an internal combustion engine of a vehicle; a lithium-ion battery electrically coupled to a second bus, in which the lithium-ion battery captures and stores electrical energy generated by a regenerative braking system when the vehicle brakes and supplies electrical power to the second bus using the electrical energy captured from the regenerative braking system such that a first portion of the second electrical power is supplied to an electrical system; and a DC/DC converter electrically coupled between the first bus and the second bus, in which the DC/DC converter controls supply of a second portion of the second electrical power to charge the lead-acid battery.

Abstract: A battery system includes a lithium ion battery that couples to an electrical system. The battery system also includes a battery management system that electrically couples to the lithium ion battery and controls one or more recharge parameters of the lithium ion battery. Additionally, the battery management system monitors one or more parameters of the lithium ion battery. Further, the battery management system controls the recharge parameters of the lithium ion battery based on at least one lithium plating model and the monitored parameters. Furthermore, the at least one lithium plating model indicates a relationship between the one or more parameters of the lithium ion battery and a likelihood of lithium plating occurring in the lithium ion battery.

Abstract: A battery module includes a housing having a top side, a bottom side, and an inside between the top side and the bottom side. The battery module also includes electrochemical cells disposed in one or more stacks in the inside of the housing. The electrochemical cells are spaced apart from each other to enable an airflow between the electrochemical cells. The battery module includes a fan on an outside of the housing and a hood disposed over the fan and configured to contact the housing to direct the airflow through an entry point into the inside of the housing. The battery module includes a vent fluidly coupling the inside and the outside of the housing. The vent vents the airflow from the inside of the housing to the outside of the housing. The battery module includes flow guide features configured to guide the airflow along the electrochemical cells.

Abstract: A battery module is disclosed that includes a stack of battery cells, where each battery cell has a terminal, and the terminal has a first alloy of a metal. The battery module has a bus bar that includes a body having a second alloy of the metal, nickel plating on at least a portion of the body, and an indentation disposed on the body, where a thickness of the nickel plating is between 0.2% and 20% of an overall thickness of the body, and a weld physically and electrically coupling the respective terminal to the bus bar. The indentation has a depth between 10% and 90% of the overall thickness, an area of the indentation is between 5% and 20% of an overall area of the body, and the nickel plating enables the weld to be stronger than a weld between the first and second alloys.

Abstract: Disclosed is a non-lead conductive cap for a battery terminal and battery. The battery may comprise a battery housing and a positive and negative terminal, the positive and negative terminal being accessible through the battery housing; wherein the positive and negative terminal further comprise an electrically conductive cap mounted on both the positive and negative terminal, wherein the electrically conductive cap does not comprise lead.

Abstract: A system includes a vent housing configured to be installed on a lower housing of a battery module at a first side of the vent housing. The vent housing has a main body having an opening on a second side of the vent housing and an internal chamber coupled to the opening. The internal chamber includes a first wall having an internal burst vent configured to open at a first pressure threshold and a second wall having a ventilation vent comprising a gas-selective permeability layer.

Abstract: A battery module includes a housing having an opening and an electrochemical cell disposed in the housing. The electrochemical cell includes a first cell surface having electrode terminals and an second cell surface substantially opposite the first cell surface. The battery module also includes a heat sink integral with the housing and disposed substantially opposite the opening of the housing and a thermally conductive adhesive bonded to the second cell surface and a heat sink surface that is facing the second cell surface. The thermally conductive adhesive includes a bonding shear strength and bonding tensile strength between the electrochemical cell and the heat sink of between approximately 5 megaPascals (MPa) and 50 MPa.

Abstract: The present disclosure includes a battery module that includes an electrochemical cell having a minor terminal. The battery module also includes a major terminal electrically coupled to the electrochemical cell, wherein the major terminal includes a base and a post extending from the base. Further, the battery module includes an electrical path between the minor terminal of the electrochemical cell and the major terminal of the battery module. The electrical path includes a bus bar having an opening that receives the post of the major terminal and a pocket that retains the base of the major terminal.

Abstract: A battery system includes a battery module, a thermal management system, and a battery system controller. The controller is configured to receive data indicative of first operational conditions of the battery module and of second operational conditions of the thermal management system, determine a desired change to the first operational conditions of the battery module by determining an amount of power available to the thermal management system and to the battery module from one or more power sources, and to enable, to effect the desired change to the first operational conditions, the one or more power sources to provide a first quantity of power to the thermal management system and a second quantity of power to the battery module, and the thermal management system to heat or to cool the battery module to a calculated extent.

Abstract: The present disclosure includes a battery module having a stack of electrochemical cells that includes terminals, a housing that receives the stack of electrochemical cells, and a bus bar carrier disposed over the stack of electrochemical cells such that bus bars disposed on the bus bar carrier interface with the terminals of the stack of electrochemical cells. The bus bar carrier includes opposing first and second guide extensions, the stack of electrochemical cells is disposed between the opposing first and second guide extensions, and the opposing first and second guide extensions physically contact a first outer electrochemical cell and a second outer electrochemical cell, respectively, of the stack of electrochemical cells to guide the terminals of the stack of electrochemical cells toward corresponding ones of the bus bars disposed on the bus bar carrier.

Abstract: The present disclosure relates to a stacked cell manufacturing scheme for battery modules. A disclosed method of manufacturing a battery module includes assembling a plurality of prismatic battery cells of the battery module into a cell stack. The method includes compressing the cell stack using an actuating clamping mechanism, inserting the cell stack into a housing of the battery module with the actuating clamping mechanism engaged with and compressing the cell stack, and removing the actuating clamping mechanism from the cell stack. The housing of battery module maintains a compression of the cell stack above a predetermined threshold in the battery module after removing the actuating clamping mechanism.