Abstract: Systems are disclosed for battery modules/systems with cooling systems. In accordance with disclosed embodiments, the cooling system may be disposed against an external surface of a housing of the battery system. The cooling system may utilize air as a coolant to remove heat generated by cells within the battery module, to prevent the cells from aging prematurely. Embodiments of the cooling system may include manifolds, channels, fins, or a combination thereof, which may route the cooling air along the surface of the battery module housing. Such features may create an isothermal temperature distribution within the battery system.

Abstract: A battery module includes a rigid external casing made, for example, of a metallic sheet material. Securement features, tabs, and so forth may be formed in the material of the casing. The casing may be made by stamping and bending metallic sheet. A liner is disposed in the casing, and one or more battery cells are disposed in the liner. The liner may comprise an insulative sheet material that is cut and folded to generally conform to the casing. The structure may include a bus bar assembly, compression members, a thermal component and other structural and functional elements.

Abstract: Battery systems and modules having external thermal management systems are provided. In one embodiment, a battery module includes a housing and at least one electrochemical cell disposed within the housing. The battery module also includes a thermal interface having a first side in contact with the at least one electrochemical cell. The battery module also includes a heat sink in contact with a second side of the thermal interface. The thermal interface is adapted to enable heat transfer from the at least one electrochemical cell to the heat sink.

Abstract: An electrical connector that has a first side configured to interface with a battery module and a second side configured to interface with a mating plug coupled to a first load. The electrical connector includes terminals extending through the first and second sides and configured to route power at a first voltage from the battery module to the mating plug; low voltage lines extending through the first and second sides, wherein the low voltage lines operate at a voltage less than the first voltage; and high voltage lines electrically coupled to the terminals via conductive leads and configured to route an electrical signal from the terminals to a second load. The electrical connector contains a secondary connection interface configured to allow access to the low and high voltage lines.

Abstract: A battery module includes a hermetically sealed battery cell assembly. The battery cell assembly includes a housing and an electrochemical cell disposed in the housing. The battery cell assembly also includes a first battery terminal coupled to and extending away from the electrochemical cell and extending through a first opening in the housing. The first opening in the housing comprises a flange. The battery cell assembly further includes a sealing ring disposed around the flange to exert a compressive force for hermetically sealing the opening.

Abstract: A current collector with improved flexibility and electrical conductivity includes at least one flexible leg coupled to a central portion of the current collector. The flexible leg extends substantially orthogonally to the central portion when a force is applied to the central portion. Specifically, the at least one flexible leg extends at least 16 percent of the outer width when a 1000 Newton loading is applied between the central portion and the outer portion.

Abstract: Provided herein are electrochemical cell element systems. One such system includes a first electrode having a desired length and an interrupted second electrode having one or more interruptions disposed between a plurality of electrode segments. The system also includes one or more separators positioned to separate the first electrode and the interrupted second electrode. The first electrode, the interrupted second electrode, and the one or more separators are wound along the length of the cell element.

Abstract: A battery system includes at least a first battery module and a second battery module, and a service disconnect unit electrically coupling the first battery module to the second battery module. The service disconnect unit comprises a bus bar that includes a first portion electrically connected to the first battery module, and a second portion electrically connected to the second battery module. The service disconnect unit also comprises a removable conductive member configured to electrically connect the first portion of the bus bar to the second portion of the bus bar.

Abstract: In an embodiment, a system includes a battery management unit (BMU) coupled to a battery pack of an xEV. Further, the BMU is configured to determine an energy remaining value for the battery pack based, at least in part, on a minimum cell temperature and a minimum cell state of charge percentage (SOC %) determined by the BMU for the battery pack.

Abstract: Systems and methods for pre-charging a bus capacitance in vehicles that receive at least a portion of their motive power from electricity generated from a battery are provided. By way of example, an embodiment includes a vehicle control unit (VCU) that receives battery pack data from a battery management unit (BMU) of each of a plurality of battery packs and determines, based on the battery pack data, which battery packs may be used to pre-charge the bus capacitance in parallel. The VCU issues commands to each of the BMUs to connect pre-charge circuits between each of the plurality of battery packs and the bus capacitance and receives status information from each of the BMUs to determine whether or not the bus capacitance was successfully pre-charged by the battery packs.

Abstract: Systems and methods for de-energizing battery packs in vehicles that receive at least a portion of their motive power from electricity generated from a battery are provided. By way of example, one embodiment includes a battery de-energizer that is configured to electrically couple to a port or receptacle, such as the service disconnect receptacle, on the vehicle and discharge the electrical energy stored in the battery pack. Another embodiment includes a battery management unit (BMU) designed to monitor one or more sensors to determine if a crash has occurred. If a crash is determined, the BMU electrically couples a battery de-energizer circuit to the battery pack to discharge the electrical energy stored in the battery pack.

Abstract: An electrochemical cell is provided including, but not limited to, a can having a side wall that is coupled to a first end and having a cover at a second end of the can to close the second end of the can, a cell element within the can, electrolyte within the can, and a safety device. The can forms a vent at the first end configured to allow gases and/or effluent to exit the can once the pressure inside the can reaches a predetermined amount. The safety device is provided adjacent a first end of the cell element and between the cell element and the first end of the housing. The safety device is configured to exert an additional force on the vent to aid in the deployment of the vent.

Abstract: A battery module includes a hermetically sealed battery cell assembly. The battery cell assembly includes a housing and an electrochemical cell disposed in the housing, wherein the housing includes a fill hole configured to receive electrolyte into the battery cell assembly. The battery cell assembly also includes a seal disposed over the fill hole and ultrasonically welded to an annular portion of the housing around the fill hole.

Abstract: Battery systems and modules having external thermal management systems are provided. In one embodiment, a battery module includes a housing and at least one electrochemical cell disposed within the housing. The battery module also includes a thermal interface having a first side in contact with the at least one electrochemical cell. The battery module also includes a heat sink in contact with a second side of the thermal interface. The thermal interface is adapted to enable heat transfer from the at least one electrochemical cell to the heat sink.

Abstract: Provided herein are electrochemical cells having improved heat collection and transfer systems. For example, one electrochemical cell includes a drawn can having a blind side and a second side opposite the blind side. The cell also includes a positive terminal disposed in the blind side of the can and electrically coupled to at least one positive electrode disposed within the can and a negative terminal disposed in the blind side of the can and electrically coupled to at least one negative electrode disposed within the can. The cell further includes a base coupled to a substantially flat edge disposed on the second side of the can. A bottom surface of the base is adapted to maintain a substantially flat configuration when coupled to a heat sink.

Abstract: A battery module includes a hermetically sealed battery cell assembly. The battery cell assembly includes a housing and an electrochemical cell disposed in the housing. The battery cell assembly also includes a first battery terminal coupled to and extending away from the electrochemical cell and extending through a first opening in the housing. The first opening in the housing comprises a flange. The battery cell assembly further includes a sealing ring disposed around the flange to exert a compressive force for hermetically sealing the opening.

Abstract: An electrical connector that has a first side configured to interface with a battery module and a second side configured to interface with a mating plug coupled to a first load. The electrical connector includes terminals extending through the first and second sides and configured to route power at a first voltage from the battery module to the mating plug; low voltage lines extending through the first and second sides, wherein the low voltage lines operate at a voltage less than the first voltage; and high voltage lines electrically coupled to the terminals via conductive leads and configured to route an electrical signal from the terminals to a second load. The electrical connector contains a secondary connection interface configured to allow access to the low and high voltage lines.

Abstract: A battery module includes a hermetically sealed battery cell assembly. The battery cell assembly includes a housing and an electrochemical cell disposed in the housing, wherein the housing includes a fill hole configured to receive electrolyte into the battery cell assembly. The battery cell assembly also includes a seal disposed over the fill hole and ultrasonically welded to an annular portion of the housing around the fill hole.