Abstract: A battery module includes a housing, a plurality of battery cells disposed in the housing, and a printed circuit board (PCB) assembly disposed in the housing. The PCB assembly includes a PCB and a shunt disposed across a first surface of the PCB. A second surface of the shunt directly contacts the first surface of the PCB, and the shunt is electrically coupled between the battery cells and a terminal of the battery module.

Abstract: The present invention provides a battery that includes a plurality of serially connected battery cells. The battery includes an upper housing and a lower housing. The battery comprises: a wire harness assembly; a middle housing that includes a plurality of cell chambers for accommodating the top sections of the plurality of serially connected battery cells. The lower housing includes a plurality of cell chambers for accommodating the bottom sections of the plurality of serially connected battery cells 102; and the middle housing has a top surface for installing the wire harness assembly (1106) and the plurality of cell chambers beneath the top surface (1102) of the middle housing.

Abstract: A lead-acid battery includes a handle assembly coupled to a polymer packaging of the battery. The handle assembly includes a woven fabric strap capable of laying substantially flat over a cover of the battery when the handle assembly is not in use. The handle assembly includes a first tab overmolded about a first end of the woven fabric strap, wherein the first tab is loaded into a first slot inset into a first end portion of the polymer packaging of the battery. The handle assembly also includes a second tab overmolded about a second end of the woven fabric strap, wherein the second tab is loaded into a second slot inset into a second end portion of the polymer packaging of the battery, and wherein a length of the first and second tabs is at least twice a width of the woven fabric strap.

Abstract: A 12 volt automotive battery system includes a first battery coupled to an electrical system, in which the first battery include a first battery chemistry, and a second battery coupled in parallel with the first battery and selectively coupled to the electrical system via a first switch, in which the second battery includes a second battery chemistry that has a higher coulombic efficiency than the first battery chemistry. The first switch couples the second battery to the electrical system during regenerative braking to enable the second battery to capture a majority of the power generated during regenerative braking. The 12 volt automotive battery system further includes a variable voltage alternator that outputs a first voltage during regenerative braking to charge the second battery and a second voltage otherwise, in which the first voltage is higher than the second voltage.

Abstract: The present disclosure is directed to a battery module having an outer housing configured to receive a plurality of electrochemical cells, in which the outer housing has a wall including an inner surface facing a cavity formed by the outer housing, an outer surface opposite to the inner surface, and an opening extending through the wall. The battery module also includes a connector barrel configured to be disposed in the opening of the wall, in which the connector barrel has a first open end, a second open end, and a body forming a hollow interior between the first open end and the second open end, in which the connector barrel has a flange disposed on the body and extending outwardly from the body, and in which the flange has a plurality of ridges configured to abut the wall.

Abstract: The present disclosure relates generally to the field of lead-acid batteries. More specifically, the present disclosure relates to handle retention features that are integrated into the packaging of lead-acid batteries. A disclosed lead-acid battery includes a battery handle assembly having a woven fabric strap with a pair of tabs, wherein each tab includes polymer overmolded about a respective end of the strap. The battery also includes a polymer packaging having a cover, wherein a top portion of the cover defines a pair of slots. Each slot is engaged with a respective tab of the battery handle assembly, and wherein each slot includes a respective retention feature that blocks the respective tab from disengaging from the slot.

Abstract: One embodiment of the present disclosure describes a battery system that includes a battery string with a first and second battery module; and a battery control system. The battery control system includes a first cell control that determines first module level operational parameters related to operation of the first battery module; a second cell control that determines second module level operational parameters related to operation of the second battery module; a string control unit communicatively that determines string level operational parameters related to operation of the battery string based at least in part on the first and second module level operational parameters; and a system control unit that determines system level operational parameters related to operation of the battery system based at least in part on the string level operational parameters; and controls operation of the battery system based at least in part on the system level operational parameters.

Abstract: The present disclosure relates generally to systems and methods for recycling lead-acid batteries, and more specifically, relates to purifying and recycling the lead content from lead-acid batteries. A system includes a reactor that receives and mixes a lead-bearing material waste, a carboxylate source, and a recycled liquid component to form a leaching mixture yielding a lead carboxylate precipitate. The system also includes a phase separation device coupled to the reactor, wherein the phase separation device isolates the lead carboxylate precipitate from a liquid component of the leaching mixture. The system further includes a closed-loop liquid recycling system coupled to the phase separation device and to the reactor, wherein the closed-loop liquid recycling system receives the liquid component isolated by the phase separation device and recycles a substantial portion of the received liquid component back to the reactor as the recycled liquid component.

Abstract: The present disclosure includes a battery module that includes a housing having a stack of battery cells. Each battery cell of the stack of battery cells includes a terminal end having at least one cell terminal and a face oriented transverse to the terminal end. The battery module also includes adhesive tape disposed between a first face of a first battery cell of the stack of battery cells and a second face of a second battery cell of the stack of battery cells, and where the adhesive tape fixedly couples the first battery cell to the second battery cell, and where a first terminal end of the first battery cell is substantially aligned with a second terminal end of the second battery cell.

Abstract: A lithium-ion battery cell includes an enclosure that includes a casing and a lid. The enclosure has an electrolyte fill hole disposed on a surface of the casing opposite the lid. An electrochemical cell is disposed within the enclosure. Additionally, a sealing patch is laser welded to the surface of the casing around the electrolyte fill hole, wherein the sealing patch is configured to seal the electrolyte fill hole.

Abstract: The present disclosure relates to a battery module that includes a housing having a first absorptive material configured to absorb a laser emission, a cover having a second absorptive material configured to absorb the laser emission, and a collar configured coupled to the housing and coupled to the cover via a laser weld. The collar includes a transparent material configured to transmit the laser emission through the collar and toward the housing or the cover.

Abstract: The present disclosure relates generally to the field of batteries and battery modules, and more specifically, relates to a system and method for manufacturing terminal assemblies for lithium-ion battery modules. A disclosed battery module includes a terminal block assembly that is secured to a polymer housing of the battery module. The terminal block assembly includes a terminal post having a post portion and a base portion that extends outward from a central axis of the post portion. The terminal block assembly also includes a bus bar coupled to the base portion of the terminal post without welding, wherein the bus bar includes a trough disposed near the terminal post. The terminal block assembly further includes a polymer portion overmolding at least the trough of the bus bar to form a drainage channel near the terminal post.

Abstract: A battery system includes a battery that couples to an electrical system. The battery system also includes a battery control module that electrically couples to the battery. The battery control module monitors at least one monitored parameter of the battery, and the battery control module recursively calculates a first capacity estimation of the battery using two linear regression models based on at least an equivalent circuit model, the at least one monitored parameter, and a Kalman filter.

Abstract: A battery system includes a battery that couples to an electrical system. The battery system also includes a battery control module that electrically couples to the battery. The battery control module monitors at least one monitored parameter of the battery, and the battery control module recursively calculates at least one calculated parameter of the battery based on at least an equivalent circuit model, the at least one monitored parameter, and a Kalman filter.

Abstract: A battery module includes a housing configured to receive a plurality of electrochemical cells, a skeletal frame coupled with the housing, and a framework disposed proximate to the skeletal frame. Moreover, the framework is substantially aligned with the skeletal frame and configured to transfer a force applied to the framework to the skeletal frame.

Abstract: A battery is provided with a battery cover having a first cover mold insert and a second cover mold insert which are interchangeable in the cover prior to molding depending at least in part on the battery's polarity configuration. The first cover mold insert has a bushing that is relatively different in dimension, size and/or shape than the bushing of the second cover mold insert, such that each bushing is adapted to receive a cast-on-strap post of a relatively different dimension, size and/or shape. The first cover mold insert may also have a terminal that is relatively different in dimension, size and/or shape than the terminal of the second cover mold insert, such that each terminal is adapted to engage a formation connector contact of a relatively different dimension, size and/or shape.

Abstract: Herein provided is an electrochemical cell electrolyte formed from ingredients comprising: water, sulfuric acid, and at least one octylphenol ethoxylate of Formula 1: where n is a natural number from at least 1 to at most 16.

Abstract: The present disclosure includes a battery module having a plurality of battery cells disposed in a housing. Each of the plurality of battery cells has a positive terminal, a negative terminal, an overcharge protection assembly, and a casing having an electrically conductive material. The overcharge protection assembly includes a vent, a first spring component, a second spring component, and an insulative component. The first spring component is coupled to the positive terminal, the second spring component is coupled to the negative terminal, the insulative component is between the first spring component and a conductive piece and between the second spring component and the conductive piece, and the vent is configured to drive the insulative component from between the first and second spring components and the conductive piece, such that the first and second spring components contact the conductive piece, when a pressure in the casing exceeds a threshold.

Abstract: The present disclosure relates to a battery module that includes a housing having a first protruding shelf along a first perimeter of the housing, a second protruding shelf along a second perimeter of the housing, where the first and second protruding shelves each include an absorptive material configured to absorb a first laser emission. The battery module also includes an electronics compartment cover configured to be coupled to the housing via a first laser weld, and a cell receptacle region cover configured to be coupled to the housing via a second laser weld. The electronics compartment cover has a first transparent material configured to transmit the first laser emission toward the first protruding shelf and the cell receptacle region cover has a second transparent material configured to transmit the first laser emission or a second laser emission toward the second protruding shelf.