Abstract: A system for sequentially interconnecting battery modules of a battery pack is disclosed. The battery pack may comprise first, second and third battery modules. Each of the first, second and third battery modules includes a first power output terminal and a second power output terminal. Each of the first power output terminals is of a first polarity and the each of the second power output terminals is of a second, opposite polarity. The system comprises a control module for providing a control signal to sequentially interconnect the battery modules, a first interconnect controller electrically disposed between the first and second battery modules, and a second interconnect controller electrically disposed between the second and third battery modules. Each of the first and second interconnect controllers includes a contactor comprising a main contact, an auxiliary contact and an actuating coil for closing the respective main contact and auxiliary contact.

Abstract: A battery module is disclosed. The battery module comprises a housing, a heat-conducting fin disposed within the housing having a first fin surface and a second fin surface, the first fin surface and the second fin surface defining a respective first housing cavity and a second housing cavity within the housing. The battery module further comprises a first battery cell disposed within the first housing cavity and engaging the first fin surface and a second battery cell disposed with the second housing cavity and engaging the second fin surface. The heat-conducting fin is adapted to conduct heat from the first and second battery cells outwardly from the housing.

Abstract: For a battery system including a battery pack and a battery management system, the battery system having output battery terminals, a method and apparatus for preventing inadvertent connection and disconnection the output battery terminals from the battery pack is disclosed.

Abstract: For a lithium-ion battery pack adapted to provide electrical power to a load via a conductor, a current shunt adapted to be disposed in series with the conductor is disclosed. The current shunt comprises one or more stacked leaves of an electrically conductive material such as nickel.

Abstract: For a battery system including a battery pack and a battery management system, the battery system having output battery terminals, a method and apparatus for preventing inadvertent connection and disconnection the output battery terminals from the battery pack is disclosed.

Abstract: For a lithium-ion battery pack adapted to provide electrical power to a load via a conductor, a current shunt adapted to be disposed in series with the conductor is disclosed. The current shunt comprises one or more stacked leaves of an electrically conductive material such as nickel.

Abstract: A battery module is disclosed. The battery module comprises a housing, a heat-conducting fin disposed within the housing having a first fin surface and a second fin surface, the first fin surface and the second fin surface defining a respective first housing cavity and a second housing cavity within the housing. The battery module further comprises a first battery cell disposed within the first housing cavity and engaging the first fin surface and a second battery cell disposed with the second housing cavity and engaging the second fin surface. The heat-conducting fin is adapted to conduct heat from the first and second battery cells outwardly from the housing.

Abstract: A battery management system for managing the voltage of a battery cell, such as a lithium ion battery, is disclosed. The battery management system comprises a semiconductor switch coupled to the battery cell, wherein the semiconductor switch is in an on condition when the voltage across the battery cell exceeds a first threshold voltage, and a microprocessor coupled to the semiconductor switch, wherein the microprocessor monitors the voltage across the battery cell when the semiconductor switch is on, and turns itself off when the when the monitored voltage is less than a second threshold voltage, thereby preventing further current drain from the battery cell.

Abstract: A lithium ion battery pack battery pack is disclosed. The battery pack comprises a housing, the housing having a sidewall and a sidewall opening extending there through, a plurality of lithium ion battery cells disposed within the housing, the battery cells having an anode terminal and a cathode terminal, first and second current collectors disposed in the housing, the first and second current collectors electrically engaging respective ones of the anode and the cathode terminals, a metal plate disposed in the sidewall opening adjacent one of the current collectors, and an electrically non-conductive barrier disposed between the adjacent one of the current collectors and the metal plate, wherein the metal plate draws heat from the adjacent one of the current collectors outwardly into the ambient environment.

Abstract: A high rate lithium battery can include a cathode composition coated on a substrate. The cathode composition can include first and second active materials and binder. The first and second active materials can have different characteristics including, for example, particle size, tap density, and amount of conductive component. The first and second active materials can be combined to achieve higher packing densities of the active material, which may allow for a higher capacity battery as compared to conventional batteries formed with a single active material.

Abstract: A lithium iron phosphate battery pack is disclosed. The battery pack includes a plurality of battery cells, arranged as groups of cells, a controller circuit, and a plurality of intercell tabs coupling the groups of battery cells to the controller circuit. The controller circuit includes a voltage sensor for monitoring the voltage across each of the groups of cells. If one of the groups has a voltage that is lower or higher than a respective lower or upper threshold voltage, the controller circuit will shut off the charge/discharge cycling of all the groups of cells. In doing so, the controller circuit protects the entire battery pack during charge/discharge cycling.

Abstract: A circuit for preventing overcharging a battery cell is disclosed. The circuit comprises a voltage detector for monitoring a voltage across a battery cell. The voltage detector is configured to determine when the voltage across the battery cell is greater than a first threshold voltage. The circuit further comprises an electronic switch responsive to the voltage detector and is configured to shunt current around the battery cell when the voltage detector has determined the battery cell voltage is greater than the first threshold voltage.

Abstract: For a circuit for preventing overcharging of a battery cell, the overcharging protecting circuit having a voltage detector for monitoring the voltage across the battery cell, a polarity protection circuit for protecting the voltage detector from a reverse polarity connection of the battery cell to the voltage detector is disclosed. The polarity protection circuit comprises a semiconductor device coupled across voltage detection inputs of the voltage detector. The semiconductor device is adapted to shunt current across the voltage detection inputs of the voltage detector when the battery cell is connected in reverse polarity to the voltage detector.

Abstract: A battery management system for managing the voltage of a battery cell, such as a lithium ion battery, is disclosed. The battery management system comprises a semiconductor switch coupled to the battery cell, wherein the semiconductor switch is in an on condition when the voltage across the battery cell exceeds a first threshold voltage, and a microprocessor coupled to the semiconductor switch, wherein the microprocessor monitors the voltage across the battery cell when the semiconductor switch is on, and turns itself off when the when the monitored voltage is less than a second threshold voltage, thereby preventing further current drain from the battery cell.

Abstract: A lithium ion battery pack battery pack is disclosed. The battery pack comprises a housing, the housing having a sidewall and a sidewall opening extending there through, a plurality of lithium ion battery cells disposed within the housing, the battery cells having an anode terminal and a cathode terminal, first and second current collectors disposed in the housing, the first and second current collectors electrically engaging respective ones of the anode and the cathode terminals, a metal plate disposed in the sidewall opening adjacent one of the current collectors, and an electrically non-conductive barrier disposed between the adjacent one of the current collectors and the metal plate, wherein the metal plate draws heat from the adjacent one of the current collectors outwardly into the ambient environment.

Abstract: A lithium ion battery pack including a housing and a top attached to an open end of the housing is disclosed. The battery pack includes plurality of battery cells, arranged in parallel and contained in the housing. The battery pack further includes cathode and anode current collectors. Each of the current collectors includes a collector plate welded to a collector plate tab. The collector plate tabs are welded to the respective cathode and anode covers of the battery cells.

Abstract: Cathode and anode structures for a battery each include one or more tabs welded to a substrate. A method of making a battery may include providing tabs welded to a substrate of each of a cathode and anode of the battery. Tabs for a cathode or anode structure may be provide from the same or similar material as the substrate of a corresponding cathode or anode.