Abstract: A battery cell assembly includes a plurality of sub-assemblies. Each sub-assembly includes a heat sink and a first frame and a second frame disposed on opposite sides of the heat sink. The sub-assemblies are stacked to form a plurality of cell pockets that receive a battery cell. The battery cell assembly further includes a plurality of tie rods for fixing the plurality of sub-assemblies together. The first frame is formed with a plurality of through holes, and the second frame is formed with a plurality of protrusions with a hole extending therethrough. The frames are brought together such that each protrusion is at least partially received in a respective through hole. The interior surfaces of corresponding protrusions and through holes of the stack of frames form a passage for one of the tie rods to extend through.

Abstract: A battery charging system includes a pre-charge control circuit for electrically coupling a plurality of power supply terminals to a plurality of load terminals. The pre-charge control circuit includes a plurality of switching elements for selectively coupling at least one of the plurality of power supply terminals and one of the plurality of power supply using one of a pre-charge current path and a standard charge current path. The pre-charge current path includes at least one pre-charge resistor in series with a positive temperature coefficient (PTC) resistor.

Abstract: Systems and methods are provided for monitoring operation of a circuit having a DC power supply, a load, and a switch element connecting the DC power supply to the load. The system includes a capacitive element coupling a first input node of a sensor element to a first interconnection node of the circuit between a first voltage supply terminal of the DC power supply and the load. The system also includes a grounding structure coupling a second input node of the sensor element to a ground plane isolated from the DC power supply. In the system, the grounding structure is positioned with respect to a second interconnection node of the circuit, between a second voltage supply terminal of the DC power supply and the load, so as to define a stray capacitance for carrying a transient signal resulting from the opening or closing of the switch element, which can be detected through the sensor element for monitoring the current switch state of the switch element.

Abstract: A redox shuttle is provided to prevent overcharge of batteries and/or shuttle current in batteries including high voltage batteries, such as high voltage lithium ion (Li-ion) batteries. An exemplary redox shuttle includes a methylated closo-monocarborate anion.

Abstract: An energy storage system is disclosed. The energy storage system may include a power control module coupled to a plurality of energy modules each including a plurality of batteries. The plurality of batteries may be placed in a plurality of containers and arranged in a plurality of parallel strings.

Abstract: Battery terminal systems are provided for coupling a first battery to a second battery. The battery terminal systems may include bases assembled to the terminals of the first battery and the second battery. The bases being coupled to a jumper to electrically couple the first battery to the second battery.

Abstract: A battery pack assembly for providing electric power to a load includes a battery pack, preferably made up of a plurality of lithium ion cells. A heating device formed of a flexible material flexes and covers at least part of the battery pack. The heating device includes a meandering heating strip. A thermal sensor is surrounded by the heating strip to sense the temperature of the battery pack. Electric current is applied to the heating strip to heat the battery pack when its temperature falls too low, thus improving performance of the battery pack. The heating device also includes a plurality of tabs extending beyond the peripheral sides of the heating device for direct connection to the cells. Thus, electric current for the heating strip is provided directly from the cells of the battery pack.

Abstract: System and methods are provided for monitoring a state of a switch element connecting a DC power supply to a load. A system includes a transformer having first and second windings, where a first end of the second winding electrically coupled to a first switch node of the switch element. The system also includes a transmit circuit configured for providing a waveform at the first winding and a sensor element having galvanically isolated input and output nodes for inducing a monitor signal at the output nodes in response to a signal at the input nodes. The system further includes a receive circuit coupled to the output nodes and configured for generating one or more output signals in response to the monitor signal. The system also includes capacitor elements for providing DC isolation for the second winding with respect to the first switch node and the sensor element.

Abstract: A battery module includes pressure release features for releasing excess pressure in a battery container, a wrap blanket disposed between a module and potting material disposed in a case to secure modules while allowing repair, replacement, recycling and/or reuse of modules and a connector.

Abstract: A battery pack assembly for providing electric power to a load includes a battery pack, preferably made up of a plurality of lithium ion cells. A heating device formed of a flexible material flexes and covers at least part of the battery pack. The heating device includes a meandering heating strip. A thermal sensor is surrounded by the heating strip to sense the temperature of the battery pack. Electric current is applied to the heating strip to heat the battery pack when its temperature falls too low, thus improving performance of the battery pack. The heating device also includes a plurality of tabs extending beyond the peripheral sides of the heating device for direct connection to the cells. Thus, electric current for the heating strip is provided directly from the cells of the battery pack.

Abstract: An assembly is disclosed which may include a serviceable unit and a current limiting device coupled to the serviceable unit. The serviceable unit may include a positive electrical terminal connection, a negative electrical terminal connection, and a plurality of energy storage devices operatively coupled to the positive electrical terminal connection and the negative electrical terminal connection to form an electrical path of the serviceable unit. The current limiting device may include a current limiting component. The current limiting component being included in the electrical path of the serviceable unit.

Abstract: Battery assemblies are disclosed which may include a plurality of battery cells removably coupled to a support. The support may include trays which are stacked. The battery cells of each tray may be electrically connected together. The battery trays may include a battery support which extends under and supports a middle portion of the battery cells of the respective battery tray. The battery support may be a thermal sink for the battery cells. The plurality of cells may be coupled to a support with a compression member including a plurality of heat transfer members.

Abstract: An electrochemical cell manufactured by coating a conductive substrate of an electrode with a disordered carbon active material using a water-based binder slurry. An exemplary binder slurry includes at least one disordered carbon material, carboxymethyl cellulose (CMC), styrene butadiene rubber (SBR), and water.

Abstract: Additives and methods for improving the performance of an electrochemical cell are described. In particular, the additives and methods may improve the performance of an electrochemical cell having a disordered carbon anode.

Abstract: Systems and methods for monitoring a state of charge of a battery are disclosed. An updated state of charge of the battery may be determined based on a measured terminal voltage of the battery, a measured current of the battery, and a value of at least one battery parameter selected from a plurality of values based on a prior state of charge of the battery.

Abstract: A battery support includes a rigid, thermally conductive upper plate having first and second opposing major surfaces. The support also includes at least one lower plate disposed on the second major surface and comprising a plurality of protrusions extending away from the second major surface and in fluid communication, the plurality of protrusions defining a first manifold portion, a second manifold portion, and plurality of non-linear passages extending along a first direction between the first and second manifolds, a cross-section of the plurality of protrusions defining the plurality of non-linear passages comprising a curved portion with a width that is at least twice the height of the curved portion. The support further includes a first conduit in fluid communication with the first manifold portion and a second conduit in fluid communication with the second manifold portion.

Abstract: A redox shuttle is provided to prevent overcharge of high voltage batteries, such as high voltage lithium ion (Li-ion) batteries. An exemplary redox shuttle includes a methylated closo-monocarborate anion.

Abstract: Systems and methods are provided for monitoring operation of a circuit having a DC power supply, a load, and a switch element connecting the DC power supply to the load. The system includes a capacitive element coupling a first input node of a sensor element to a first interconnection node of the circuit between a first voltage supply terminal of the DC power supply and the load. The system also includes a grounding structure coupling a second input node of the sensor element to a ground plane isolated from the DC power supply. In the system, the grounding structure is positioned with respect to a second interconnection node of the circuit, between a second voltage supply terminal of the DC power supply and the load, so as to define a stray capacitance for carrying a transient signal resulting from the opening or closing of the switch element, which can be detected through the sensor element for monitoring the current switch state of the switch element.

Abstract: A battery assembly includes a first cell and a second cell adjacent the first cell. A first insulator and a second insulator extend over and encapsulate first electrode and second electrode. A shell extends over the first and second insulators thereby encapsulating the first and second insulators. A mechanical connection is defined between the first insulator of the first cell and the second insulator of the second cell.

Abstract: Structural and thermal management component. In at least one exemplary embodiment of a structural and thermal management component of the present disclosure, the component comprises a base portion defining an upper surface and a lower surface. An exemplary component further comprises a plurality of fins extending from the upper surface of the base portion at least substantially extending a length of the base portion, the plurality of fins configured to dissipate heat away from a structure positioned adjacent thereto, the plurality of fins and the base portion forming a structurally-rigid unitary body. In at least one embodiment, the structurally-rigid unitary body of the present disclosure is extruded from a single portion of a metal.