Abstract: Methods of forming encapsulated electrochemical and/or ionically conducting particles as well as their use in manufacturing electrochemical cells are described.

Abstract: Embodiments for configuring a battery system are described and may include a stack of commonly connected controller circuit boards configured to connect to any battery system to provide an expandable current/power capacity to meet flexible battery architectures. The controller circuit boards in the stack may be connected to each other. For example, multiple controller circuit boards may each include one or more commonly connected identical components. The common connections among the multiple controller circuit boards may enable the various components, e.g., switches, to be controlled together by common control signals from a processor. Embodiments related to battery systems with flexible connection architectures between adjacent sets of electrochemical cells are also disclosed. For example, multiple pairs of electrical terminals may be configured to be electrically connected to multiple electrical energy storage devices using a plurality of switches (e.g., FET switches) to provide a commanded configuration.

Abstract: The invention is directed to a process for forming a particle film on a substrate. Preferably, a series of corona guns, staggered to optimize film thickness uniformity, are oriented on both sides of a slowly translating grounded substrate (copper or aluminum for the anode or cathode, respectively). The substrate is preferably slightly heated to induce binder flow, and passed through a set of hot rollers that further induce melting and improve film uniformity. The sheeting is collected on a roll or can be combined in-situ and rolled into a single-cell battery. The invention is also directed to products formed by the processes of the invention and, in particular, batteries.

Abstract: Embodiments of a device and methods to operating the same are described that can reliably monitor a plurality of battery systems including a wireless mesh network. The plurality of battery systems are respectively coupled to a plurality of communication devices each configured to receive battery information regarding the battery system coupled thereto. Each communication device may include a communication interface and configured to communicate with other communication devices on a wireless mesh network. Battery information regarding a battery system may be transmitted through the wireless mesh network to reach a gateway. Battery information may further be transmitted from the gateway to a user device, the Internet, or another network for monitoring the battery systems in a communication protocol different from the wireless mesh network. A gateway may be a dedicated gateway device or any of the communication devices on the wireless network.

Abstract: The invention is directed to a process for forming a particle film on a substrate. Preferably, a series of corona guns, staggered to optimize film thickness uniformity, are oriented on both sides of a slowly translating grounded substrate (copper or aluminum for the anode or cathode, respectively). The substrate is preferably slightly heated to induce binder flow, and passed through a set of hot rollers that further induce melting and improve film uniformity. The sheeting is collected on a roll or can be combined in-situ and rolled into a single-cell battery. The invention is also directed to products formed by the processes of the invention and, in particular, batteries.

Abstract: Thermal fuses and related methods of operation are disclosed. In some embodiments, a thermal fuse may include an insulating component and two electrodes operatively connected to the insulating component. Based on a difference in the thermal coefficients of expansion, the insulating component may expand axially relative to the electrodes with increasing temperature. As the insulating component expands the two electrodes may be moved axially apart to transition between an open and closed configuration. In some embodiments, the thermal fuse may transition between the open and closed configuration depending on whether or not an operating temperature of the thermal fuse is above or below a threshold temperature.

Abstract: Methods of forming encapsulated electrochemical and/or ionically conducting particles as their use in manufacturing electrochemical cells are described.

Abstract: Powderized solid-state electrolytes and electroactive materials as well as related methods of manufacturing and use are disclosed. In one embodiment, an ionically conductive powder comprises a plurality of ionically conductive particles. The ionically conductive particles may comprise an ionically conductive salt dissolved in a thermoplastic polymer, with optional components (e.g., electroactive and/or inorganic solid particles) dispersed within. Related methods of producing these ionically conductive powders are also disclosed including, but are not limited to, low-temperature milling, spray drying, and aerosol polymerization. Embodiments related to using the resultant ionically conductive powders in a spray deposition process are also described.

Abstract: Systems, methods and devices for managing power systems and energy storage devices, such as a rechargeable batteries, at operational temperature limits of the energy storage device. The systems control the operation of a charging device in a low temperature operating mode below a charging low temperature limit of the energy storage device at which the energy storage device may be damaged or dangerous if in a charging state. The system controls a current output of the charging device to provide at least some of the power required to power a heater which heats the energy storage device while at the same time avoiding the energy storage device going into a charging state, based on the one or more sensor signals.

Abstract: Methods of forming encapsulated electrochemical and/or ionically conducting particles as well as their use in manufacturing electrochemical cells are described.

Abstract: A power charging system for a towing vehicle and towed vehicle combination for transferring high charging power from a charging device in the towing vehicle to an energy storage device on the towed vehicle. The power charging system is capable of safely transferring at least 1 kW of charging power. The power charging system includes a controller and sensors operably coupled to the controller via a communication system for safely powering the system when needed to charge the energy storage device, and safely de-powering the system prior to disconnecting the high-power charging circuit between the towing vehicle and the energy storage device.

Abstract: A system for forming a particle layer on a substrate may include at least one sprayer and at least two masks configured to selectively mask a substrate in a first region and second region of the substrate. The at least one sprayer may be configured to spray particles at the substrate, where the at least two masks maintain the first region and second region substantially free of the deposited material. A heater may be employed to heat the substrate as the particles are sprayed by the at least one sprayer onto the substrate.

Abstract: Embodiments of a device and methods to operating the same are described that can provide high level status information about a battery having multiple modular battery packs which may be arranged in different numbers and/or electrical configurations depending on the specific application. In some embodiments, a smart hub is in communication with battery packs within the battery and configured to selectively query low level status information associated with individual battery packs based on a stored pack configuration that can be updated by a user. The device allows more efficient provision of battery information during flexible assembly and connection of the battery packs.

Abstract: A system for forming a particle layer on a substrate may include at least one sprayer and at least two masks configured to selectively mask a substrate in a first region and second region of the substrate. The at least one sprayer may be configured to spray particles at the substrate, where the at least two masks maintain the first region and second region substantially free of the deposited material. A heater may be employed to heat the substrate as the particles are sprayed by the at least one sprayer onto the substrate.

Abstract: Powderized solid-state electrolytes and electroactive materials as well as related methods of manufacturing and use are disclosed. In one embodiment, an ionically conductive powder comprises a plurality of ionically conductive particles. The ionically conductive particles may comprise an ionically conductive salt dissolved in a thermoplastic polymer, with optional components (e.g.,electroactive and/or inorganic solid particles) dispersed within. Related methods of producing these ionically conductive powders are also disclosed including, but are not limited to, low-temperature milling, spray drying, and aerosol polymerization. Embodiments related to using the resultant ionically conductive powders in a spray deposition process are also described.