Abstract: A battery module with one or more battery cells and a heat exchange member placed in thermal communication with the battery cell, and a method of making a heat pipe system from the heat exchange member. The heat exchange member includes a container with a heat transfer fluid disposed therein. In one form, the heat transfer fluid is capable of going through a phase change as a way to absorb at least a portion of heat present in or generated by battery cell. A pressure control device cooperates with the container and heat transfer fluid such that upon attainment of a predetermined thermal event within the battery cell, the pressure control device permits liberation of at least a portion of the heat transfer fluid to an ambient environment, thereby relieving pressure on the container and removing some of the excess heat caused by the thermal event.

Abstract: An electrified powertrain for a vehicle includes a battery system configured to switch individual battery modules between series, parallel, and bypassed connections, thereby eliminating the need for a DC-DC converter. The battery system is also configured to generate (via a set of drive switches) AC voltages for an electric motor, thereby eliminating the need for an inverter. Control methods for the electrified powertrain, which could be implemented in a controller of the vehicle, include controlling the switches of the battery system to maintain a constant desired output voltage during both discharging and recharging. The control methods also include controlling the series, parallel, and/or bypass switches of the battery system to bypass malfunctioning battery modules and/or to decrease the output voltage of the battery system below a voltage threshold that requires electrical isolation.

Abstract: An electrified powertrain for a vehicle includes a battery system configured to switch individual battery modules between series, parallel, and bypassed connections, thereby eliminating the need for a DC-DC converter. The battery system is also configured to generate (via a set of drive switches) AC voltages for an electric motor, thereby eliminating the need for an inverter. Control methods for the electrified powertrain, which could be implemented in a controller of the vehicle, include controlling the switches of the battery system to maintain a constant desired output voltage during both discharging and recharging. The control methods also include controlling the series, parallel, and/or bypass switches of the battery system to bypass malfunctioning battery modules and/or to decrease the output voltage of the battery system below a voltage threshold that requires electrical isolation.

Abstract: An electric vehicle includes a transmission, motor, rechargeable energy storage system (RESS), auxiliary power unit (APU), and a controller. The APU has a pair of rings, at least one of which rotates with respect to the other. One ring is coaxial with and radially within the other. Ring rotation generates current in windings. A gear element is in driving connection with the rotatable ring. The APU includes an engine disposed radially within the inner ring, and a power takeoff mechanism coupled to the gear element. The controller energizes the APU to rotate a ring. A method includes positioning the APU in a vehicle body compartment, affixing an outer ring of windings to a compartment wall, and positioning a rotatable inner ring having permanent magnets radially within and coaxial with the outer ring. The engine is positioned radially within the inner ring. A power takeoff mechanism connects to the inner ring.

Abstract: A method of forming an electrode of a lithium ion secondary battery includes combining a binder and active particles to form a mixture, coating a surface with the mixture to form a coated article, translating the article along a first plane, cutting a first plurality of carbon fibers, each having a first average length, to form a second plurality of carbon fibers, each having a longitudinal axis and a second average length that is shorter than the first average length, inserting the second plurality of fibers into the mixture layer so that the longitudinal axis of each of at least a portion of the second plurality of fibers is not parallel to the first plane to form a preform, wherein the second plurality of fibers forms a truss structure disposed in three dimensions within the mixture layer, and heating the preform to form the electrode. An electrode is also disclosed.

Abstract: A customizable energy system for a vehicle includes a plurality of interchangeable energy modules, wherein at least one of the plurality of interchangeable energy modules is an energy storage module configured for storing a first form of energy. The customizable energy system also includes a receptacle defining at least one cavity therein and configured for operatively communicating with the plurality of interchangeable energy modules, wherein the at least one cavity is configured for receiving any one of the plurality of interchangeable energy modules. Each of the plurality of interchangeable energy modules has a substantially similar shape and is interchangeably insertable into and removable from the at least one cavity.

Abstract: One embodiment includes a lithium-ion battery negative electrode including one or more low-melting point alloys that react with lithium.

Abstract: One embodiment includes a liquid-metal alloy negative electrode for a lithium-ion battery. The electrode may also include a porous matrix that comprises a polymer matrix material, a hydrogel material, or a ceramic material.

Abstract: A cluster or array of reference electrode materials is prepared and used to monitor the state of charge of positive and negative active electrode materials of a lithium-ion cell. The reference electrode materials are composed so as to provide useful electrochemical potential values when placed in the same electrolyte in proximity with a positive or negative electrode. The array of reference electrodes includes at least two electrically discrete instances of reference electrode materials. Such duplication of reference material in the array permits confirmation of the present quality and activity of a reference material used for evaluation of positive and/or negative electrode material in a lithium-ion cell.

Abstract: A battery module with one or more battery cells and a heat exchange member placed in thermal communication with the battery cell, and a method of making a heat pipe system from the heat exchange member. The heat exchange member includes a container with a heat transfer fluid disposed therein. In one form, the heat transfer fluid is capable of going through a phase change as a way to absorb at least a portion of heat present in or generated by battery cell. A pressure control device cooperates with the container and heat transfer fluid such that upon attainment of a predetermined thermal event within the battery cell, the pressure control device permits liberation of at least a portion of the heat transfer fluid to an ambient environment, thereby relieving pressure on the container and removing some of the excess heat caused by the thermal event.

Abstract: One exemplary embodiment includes an electrode including an embedded compressible or shape changing component.

Abstract: An electric vehicle includes a transmission, motor, rechargeable energy storage system (RESS), auxiliary power unit (APU), and a controller. The APU has a pair of rings, at least one of which rotates with respect to the other. One ring is coaxial with and radially within the other. Ring rotation generates current in windings. A gear element is in driving connection with the rotatable ring. The APU includes an engine disposed radially within the inner ring, and a power takeoff mechanism coupled to the gear element. The controller energizes the APU to rotate a ring. A method includes positioning the APU in a vehicle body compartment, affixing an outer ring of windings to a compartment wall, and positioning a rotatable inner ring having permanent magnets radially within and coaxial with the outer ring. The engine is positioned radially within the inner ring. A power takeoff mechanism connects to the inner ring.

Abstract: One embodiment includes a method for recharging a lithium ion battery, including providing a lithium ion battery comprising used liquid electrode material; removing said used liquid electrode material from said lithium ion battery; and, introducing a relatively unused liquid electrode material into the lithium ion battery to replace the used liquid electrode material.

Abstract: A method of mitigating battery cell failure is provided. In one embodiment, the method includes providing a coupling between a battery pack and an internal combustion engine exhaust system, the coupling comprising: a duct positioned between the battery pack and the internal combustion engine exhaust system, the duct including at least one one-way valve positioned to allow battery cell exhaust to pass from the battery cell to the internal combustion engine exhaust system; detecting a thermal event; activating a fan, an air pump, or both in response to the thermal event to force the battery cell exhaust through the coupling; and treating the battery cell exhaust in the internal combustion engine exhaust system. Battery failure mitigation systems are also described.

Abstract: A customizable energy system for a vehicle includes a plurality of interchangeable energy modules, wherein at least one of the plurality of interchangeable energy modules is an energy storage module configured for storing a first form of energy. The customizable energy system also includes a receptacle defining at least one cavity therein and configured for operatively communicating with the plurality of interchangeable energy modules, wherein the at least one cavity is configured for receiving any one of the plurality of interchangeable energy modules. Each of the plurality of interchangeable energy modules has a substantially similar shape and is interchangeably insertable into and removable from the at least one cavity.

Abstract: An electrochemical device includes an electrochemical cell having a first volume for receiving a liquid reactant negative electrode material, a second volume for receiving a liquid reactant positive electrode material, and a lithium ion exchange membrane positioned between the first and second volumes. Liquid reactant negative electrode material includes lithium or a material including lithium. The lithium ion exchange membrane facilitates a lithium ion exchange reaction between the liquid reactant materials to generate a lithium depleted negative electrode material and a lithium enriched positive electrode material.

Abstract: A method of forming an electrode of a lithium ion secondary battery includes combining a binder and active particles to form a mixture, coating a surface with the mixture to form a coated article, translating the article along a first plane, cutting a first plurality of carbon fibers, each having a first average length, to form a second plurality of carbon fibers, each having a longitudinal axis and a second average length that is shorter than the first average length, inserting the second plurality of fibers into the mixture layer so that the longitudinal axis of each of at least a portion of the second plurality of fibers is not parallel to the first plane to form a preform, wherein the second plurality of fibers forms a truss structure disposed in three dimensions within the mixture layer, and heating the preform to form the electrode. An electrode is also disclosed.

Abstract: One embodiment includes a lithium-ion battery negative electrode including one or more low-melting point alloys that react with lithium.

Abstract: One embodiment includes a liquid-metal alloy negative electrode for a lithium-ion battery.

Abstract: A method of mitigating battery cell failure is provided. In one embodiment, the method includes providing a coupling between a battery pack and an internal combustion engine exhaust system, the coupling comprising: a duct positioned between the battery pack and the internal combustion engine exhaust system, the duct including at least one one-way valve positioned to allow battery cell exhaust to pass from the battery cell to the internal combustion engine exhaust system; detecting a thermal event; activating a fan, an air pump, or both in response to the thermal event to force the battery cell exhaust through the coupling; and treating the battery cell exhaust in the internal combustion engine exhaust system. Battery failure mitigation systems are also described.