Abstract: The present invention is notably directed to methods and systems for protecting a pre-charge circuit. The present invention is further directed to related computer-implemented program product. The method comprises monitoring the current flowing through the current limiting device, calculating the energy loading of the current limiting device over time, and managing the system state to prevent damaging operation of the pre-charge circuit.

Abstract: The present invention is notably directed to methods for estimating a degradation of an electronically controlled electro-mechanical switch. The methods comprise determining a change of state of the contactor. They also comprise, computing, for each determined change of state, a wear increment WI of the contactor by: identifying a wear coefficient using a mapping between a last measured current through the contactor and a current range associated with a given wear coefficient; computing the actual wear WN of the contactor by adding the computed wear increment WI to a former known wear WI?1 of the contactor.

Abstract: Provided is a modular, scalable and decentralized high voltage battery system that employs signaling and communications between a plurality of battery modules of the system without a central battery management controller. Via signaling mechanisms, each battery module of the plurality of battery modules of the system can perform precharging, discharging, charging, and safety functions in a manner that is extensible regardless of a number of battery modules in the system in series and in parallel and in a manner that does not require significant operator intervention.

Abstract: Provided is a modular, scalable and decentralized high voltage battery system that employs signaling and communications between battery modules of the system without a central battery management controller. Via signaling mechanisms, the individual battery modules of the system can perform precharging, discharging, charging, and safety functions in a manner that is extensible regardless of a number of battery modules in the system in series and parallel and in a manner that does not require significant operator intervention.

Abstract: A method may include activating two or more bypassable battery modules in succession through a current-limiting circuit to precharge an application bus from a power source.

Abstract: The invention is directed to a system for controlling battery current. In some embodiments, the system comprises a first lithium-ion (Li-ion) battery, the first battery having a first state-of-charge (SOC) and comprising a first battery controller and a first battery charger; and a second Li-ion battery in series with the first battery, the second battery having a second SOC and comprising a second battery controller and a second battery charger. In some embodiments, at least one of the first battery controller or the second battery controller controls a charge current flowing through at least one of the first battery and the second battery, wherein control of the charge current is transferred from the first battery to the second battery based at least partially on whether an overhead voltage is present across the first battery charger or the second battery charger.

Abstract: A smart charge connector is provided incorporating a switching feature allowing the cells in a multi-cell battery to be uniformly charged. When engaged with a charger, the smart connector will connect the cells in parallel so that all cells within the same battery will be charged uniformly to the same voltage level eliminating the uneven charging that occurs when cells are charged in series connected strings. During normal operation the connector connects the cells of the battery in series to supply a battery output voltage. However, when the connector is engaged with a charger, the cells are connected in parallel to be charged by a source of electrical power at a voltage higher than the battery output voltage. The connector includes a number of switch contacts that are activated when the connector is engaged with the charger allowing the cells to be charged in parallel. The switch contacts automatically reconnect the cells in series upon removal of the charger.

Abstract: An electrochemical cell, including a jelly-roll type electrode stack, and a method for making such cell. The electrochemical cell includes folded electrode portions which form a plane recessed from the end of the electrode stack. The folded electrode portions are preferably formed by making pairs of slits in the electrode end and bending over the electrode portions between each pair of slits. The recessed plane forms a large area to which a current collection tab is subsequently connected. A coating may be applied to the folded portions of the electrode to further increase the contact area with the current collection tab by eliminating the slight variations in the recessed plane which are due to the overlap of the folded electrode portions.

Abstract: An explosion-proof valve electrical disconnect assembly incorporates a vent valve contact disk which seals the can of a compact electrochemical cell and which faces a juxtaposed stripper contact disk welded at the center by a weld nugget at a weld point, forming a rigid, preferably increased thickness, mass. The underlying stripper contact disk is weakened about the weld point, surrounding the weld nugget to ensure pull-through of the stripper contact disk portion immediately adjacent to the weld connection to effect initial electrical separation of the two contact disks. Subsequent rupture of the vent valve contact disk releases high pressure gas internally from the cell. A semi-rigid assembly cup may support a rigid grommet functioning to sandwich the vent valve contact disk and the stripper contact disk facilitated by crimping of the can top about a deformable L-shaped cross-section annular assembly cup.

Abstract: A separator system for a LiAl/FeS.sub.x electrochemical cell includes microporous sintered metal particle retainer screens fabricated by cold compacting, tape casting or plasma spraying, followed by sintering. The separator may consist of Al.sub.2 O.sub.3 or MgO powder, AlN microporous particles, AlN microporous disk or ceramic standoff sandwiched between two screens or Al.sub.2 O.sub.3 or MgO powder plasma sprayed onto one screen surface. The various separator system combinations are impregnated with 20% to 50% by volume electrolyte salt for ionic conductivity. Pore size is less than 10 .mu.m, excluding electrode particles from reaching the separator.

Abstract: A loosely wrapped multi-layer thermal insulation structure is provided by coextensively winding, a continuous thin metal foil and a superimposed continuous low thermal conductivity porous material spacer about a mandrel, preferably functioning as an inner metallic shell for such loosely wound metal foil and spacer assembly. A plurality of narrow low thermal conductivity porous material strips are interposed between adjacent turns of the spiral wound metal foil and spacer assembly at laterally spaced positions throughout the assembly to form localized, narrow dense wound material areas defining an integral load-bearing system for the thermal insulation structure. Longitudinally extending permanent getter material strips may be bonded to the outer peripheral surface of the inner metallic shell defining gas passages for gas diffusion within the metal foil and spacer assembly. The metal foil may be perforated to facilitate that action.

Abstract: Flanged U-shaped cup members abut the exterior of the negative electrode and positive electrode of a Li alloy/FeS.sub.x multi-cell battery array and function to form a peripherally sealed structural enclosure for these elements, while capturing and maintaining ceramic seal rings between respective flanges. The flanged cup-like members act in conjunction with either back-to-back similarly shaped and sized inverted flanged cup-like members or C-shaped upper and lower spacer rings whose vertical height is double that of the electrodes. At least one of the flanges of the electrode containment structure extends radially outwardly and downwardly oblique from the other flange of the C-shaped support structure, and the periphery thereof is welded to the periphery of a similar diameter juxtaposed cell cover ring to form a complete multi-cell envelope for the battery by welding of two seal assemblies together.

Abstract: A design and process for making hermetically sealed thermocompression feedthrough and peripheral seal for high temperature Li Alloy FeS.sub.x battery cells and battery enclosures. The selected materials and processes parameters are developed to match the high temperature Li Alloy/FeS.sub.x system.

Abstract: A pressure vessel for pressurized secondary cells is disclosed. The vessel includes a generally cylindrical container having both ends closed by substantially flat circular discs. The container has a diameter dimension substantially greater than its axial dimension. A mechanism is provided for supporting a plurality of substantially rectangular stacked electrode plates within the container. A pair of sealed terminal connectors pass through the container, and a terminal assembly mechanism is disposed within the container for directly interconnecting the stacked plates to each terminal connector.

Abstract: A small to miniature pressurized secondary cell of planar configuration has a case comprising a generally cylindrical sidewall open at one end and closed at the other end by a circular end wall. The open end of the case is closed by a cover which includes a positive terminal electrically isolated from the case. A plurality of substantially rectangular positive and negative stacked electrode plates with interleaved separator components are supported within the cell to define chordal volumes between the stacked electrode plates and the cylindrical sidewall of the cell sufficient to establish equilibrium gas pressures within the cell. The positive electrode plates are connected to the positive terminal and the negative electrode plates are electrically grounded to the case. Compressible electrolyte reservoir plates can also be provided at one or both ends of the stacked electrode plates to provide additional electrolyte during the service life of the cell and to absorb expansion of the electrode stack.

Abstract: A localized surface area of an open foam type metal substrate of an electrochemical cell electrode, where the substrate is filled with active material and compressed, is subjected to light pressure scrubbing by a heated soldering iron tip subjected to ultrasonic vibration to quickly dislodge the active material network of the open foam type metal substrate. Compressed air at approximately 100 psi is blown through the open foam type metal substrate to remove dislodged active material particles from the foam type metal substrate to permit effective welding of a metal terminal connection to the substrate at the localized area after cleaning. Alternatively, both opposite surfaces of the open foam type metal substrate at the localized area may be brushed to initially dislodge the active material from the pores of the open foam type metal substrate and the dislodged particles blown through the substrate from one surface to the other.

Abstract: A high-temperature bipolar battery consisting of a plurality of stacked individual cells. A first, thermal-sprayed electrode or electrolyte resistant material ceramic layer is sprayed to the exterior of the face-to-face stacked array and onto the peripheral faces of the battery metal end plates remote from the individual cells of a thickness sufficient to virtually eliminate all through pores therein. A second thermal-sprayed ceramic layer is of a thickness sufficient to form a metal support and containment structure of the bipolar battery stack. The thermal-sprayed layers have similar coefficients of thermal expansion (CTE). A metal cup surrounds and encloses at least one of the electrodes of each individual cell tending to form an inter-cell seal between the thermal-sprayed ceramic layer and the metal cup to prevent communication of electrolyte from cell to cell.

Abstract: A pressure venting device for a battery casing includes two semi-circular concavities extending upwardly from the bottom surface of the casing, two oppositely disposed bridges interrupting the concavities and two weakening or score lines disposed laterally and offset from the bridges. Since the score lines are formed in a flat area of the bottom surface of the battery casing, venting will occur consistently at a predetermined pressure range.

Abstract: A pressure relief vent on a container includes a flat diaphragm fastened to the exterior of a container so as to cover an opening in the container. The diaphragm is fastened to the container at its perimeter and at at least one point within its perimeter. The shape of the peripheral fastening seam and the number of and size of the point fastenings determine and stabilize the vent pressure at which the diaphragm ruptures.

Abstract: In a preferably cylindrical sheet metal casing to be hermetically sealed and having a thinwall portion, the improvement in a vent for the casing which ruptures when internal casing pressure exceeds a given value, the vent including at least one vent-forming rib projecting outward from a circular end wall thereof, said rib having formed therein a vent-forming groove which extends transversely of the length of the rib only part way along the transverse contour thereof, so that the groove ends are spaced from the base of the rib preferably a distance at least equal to the end wall thickness.