Abstract: A mechanical design of a rechargeable battery cell (e.g., a Lithium-ion battery) disposed inside of a prismatic can, for use in electric vehicles and other electric-powered devices. The improved design uses a thermally conductive insert to divide the battery cell into two adjacent volumes that each hold a pair of stacked layers of a battery cell. This thermally conductive insert conducts heat from the center of the battery cell during battery recharging to actively-cooled channels disposed in a pair of cooling manifolds that are disposed on two vertical sides of the battery cell. Alternatively, or additionally, an actively-cooled bottom cold plate can be used. The pair of stacked battery layers can each be wound in a “jelly-roll” geometric configuration. The thermally conductive insert may be made of aluminum, aluminum alloy, copper, or copper alloy, and combinations thereof.

Abstract: A battery pack includes a battery pack enclosure surrounded by an external environment and housing battery cells. The battery pack enclosure includes a tray having a first compartment housing the battery cells and a second compartment configured to collect high-temperature gas emitted by the battery cell(s) during a thermal runaway and expel the gas to the external environment. The battery pack enclosure also includes a cover configured to engage the tray and seal the enclosure. The first compartment is arranged between the second compartment and the cover. The battery pack also includes a temperature-sensitive component arranged inside the enclosure between the second compartment and the cover. The battery pack additionally includes a vent channel fluidly connecting the first and second compartments and configured to direct the high-temperature gas from the first compartment to the second compartment, thereby diverting the gas away from the temperature-sensitive component.

Abstract: Presented are battery assemblies with gas manifold liners and support tray seals for optimized gas venting, methods for making/using such battery assemblies, and vehicles equipped with such battery assemblies. A battery assembly, such as a rechargeable high-voltage traction battery pack, includes a support tray that seats thereon a cold plate. The cold plate is formed with a thermally conductive material and includes a gas manifold that exhausts gases from the battery assembly. At least one battery cell is supported on the cold plate and includes a cell case that contains a galvanic electrochemical cell and has a cell vent fluidly coupled with the gas manifold. A manifold liner is located within and abuts opposing walls of the gas manifold. The manifold insert includes one or more thermal barrier layers, each formed with a thermally insulating material, and one or more electrical barrier layers, each formed with an electrically insulating material.

Abstract: A dual-function, combined thermal/structural structure for simultaneously holding and cooling one or more battery cells that are stacked inside of a battery pack. The dual-function structure comprises: (1) a first cooling plate with a first plurality of parallel internal coolant channels; (2) a second cooling plate with a second plurality of parallel internal coolant channels; (3) a first structural side plate; (4) a second structural side plate; and (5) fasteners for joining the first cooling plate, the second cooling plate, the first structural side plate, and the second structural side plate together into an rectangular, box-like, cooled structure. The first and second cooling plates simultaneously structurally support and thermally cool one or more battery cells on at least two opposite sides. Additional horizontal cooling plates can be used to thermally cool and structurally support the underside of each battery cell, thereby providing a 3-sided cooling effect.

Abstract: A method for assembling a rechargeable energy storage system includes assembling a plurality of cell modules into an upper structure of an enclosure, wherein the plurality of cell modules are composed of a plurality of battery cells and a plurality of collectors, wherein the plurality of collectors are arranged to electrically connect the battery cells; inverting the enclosure including the plurality of cell modules assembled therein; filling the enclosure with a liquified potting compound; curing the liquified potting compound to form a solidified potting compound; and assembling a bottom structure onto the upper structure of the enclosure to form a plurality of longitudinal channels.

Abstract: A battery module includes a first battery cell and a neighboring second battery cell, and an insulating member positioned therebetween. The battery module also includes a battery module enclosure surrounded by an external environment and configured to house each of the first battery cell, the second battery cell, and the insulating member. The battery module additionally includes a battery module cover mounted to the battery module enclosure. The battery module cover includes a vent feature configured to expel high temperature gases from the first battery cell and divert the high temperature gases away from the second battery cell directly to the external environment. The cover is thereby configured to minimize transfer of the high temperature gases from the first battery cell to the second battery cell and control propagation of a thermal runaway event in the battery module.

Abstract: A rechargeable energy storage system includes a battery having a plurality of cells. The battery pack includes a first end, a second end, a first side, and a second side, an upper surface, and a lower surface. A battery support includes a support surface supporting the plurality of cells. The support surface has a first end portion, a second end portion, a first side portion and a second side portion. A ventilation member is arranged below the battery support between the first side portion and the second side. The ventilation member includes a surface section, and a plurality of wall members that project outwardly of the surface section. The plurality of wall members define a plurality of ventilation channels.

Abstract: A vehicle frame includes a first vehicle frame side rail and a second vehicle frame side rail spaced laterally from the first vehicle frame side rail. An upper battery enclosure having an upper wall and a pair of side walls. A cross beam extends through a respective pair of apertures in the pair of side walls of the battery enclosure and through an aperture in the first vehicle frame side rail and an aperture in the second vehicle frame side rail. A battery tray is secured below the pair of side walls of the upper battery enclosure.

Abstract: A battery mounting system for a vehicle including a mounting member configured to connect to an underbody. The mounting member includes a first end, a second end, a first side, and a second side. The second end is opposite to and spaced from the first end along a first axis and the second side is opposite to and spaced from the first side along a second axis that is orthogonal to the first axis. A cross-member extends between the first side and the second side. The cross-member forms a first battery module zone and a second battery module zone. The second battery module zone being spaced from the first battery module zone along the first axis. A first battery module is arranged in the first battery module zone below the vehicle underbody and a second battery module is arranged in the second battery module zone below the vehicle underbody.

Abstract: A structural battery pack includes a bottom cover, a bottom cell carrier, multiple battery cells, a cooling ribbon, a top cell carrier, and a top cover. The bottom cover has a rectangular shape that defines a longitudinal direction and a lateral direction. The bottom cell carrier is coupled to the bottom cover, and defines multiple bottom holders. The bottom holders are arranged in a hexagon pattern that defines multiple rows in the longitudinal direction and multiple columns in the lateral direction. The top cell carrier is coupled to the top cover, defines multiple top holders, and includes an interconnect board that interconnects the battery cells. The top holders are arranged in the hexagon pattern. The battery cells are installed in the bottom cell carrier and the top cell carrier. Each battery cell has a cylindrical shape. The cooling ribbon is installed between the battery cells along the rows.

Abstract: Presented are battery assemblies with integrated fuel tanks, methods for making/using such battery assemblies, and fuel cell electric vehicles having rechargeable traction battery packs with integrated fiber-composite hydrogen fuel tanks. A rechargeable energy storage system (RESS) assembly includes a battery pack housing with an internal battery module compartment located between two tank mounting cavities. Each mounting cavity is recessed into a respective lateral side of the battery pack housing. Multiple rechargeable battery modules are electrically interconnected with one another and mounted inside the battery module compartment. Each battery module contains multiple battery cells, such as a stack of series-connected lithium-ion pouch cells. A fuel tank is mounted in each of the tank mounting cavities on the lateral sides of the battery pack housing.

Abstract: A thermal management system for one or more components of a vehicle includes one or more heat generating components, and one or more compartments to contain the one or more heat generating components. One or more vent openings are located in the one or more compartments. Each vent opening of the one or more vent openings are closed by a thermally active material, such that when exhaust gas from the one or more components interacts with the thermally active material, the one or more vent openings are opened allowing for removal of the exhaust gas from the compartment. One or more vent manifolds are located adjacent to the one or more vent openings. The one or more vent manifolds are configured to direct the exhaust gas to ambient through one or more manifold openings in the one or more vent manifolds.

Abstract: A battery module includes a first battery cell and a neighboring second battery cell, and an insulating member positioned therebetween. The battery module also includes a battery module enclosure surrounded by an external environment and configured to house each of the first battery cell, the second battery cell, and the insulating member. The battery module additionally includes a battery module cover mounted to the battery module enclosure. The battery module cover includes a vent feature configured to expel high temperature gases from the first battery cell and divert the high temperature gases away from the second battery cell directly to the external environment. The cover is thereby configured to minimize transfer of the high temperature gases from the first battery cell to the second battery cell and control propagation of a thermal runaway event in the battery module.

Abstract: An electrochemical assembly includes a case defining an interior region, an electrochemical cell, a device, and a pressure relief valve. The electrochemical cell is disposed within the interior region. The device includes a spreader component. The spreader component includes a polymer matrix and an additive embedded in the polymer matrix. The additive includes an endothermic phase change material, a flame retardant material, an intumescent material, or any combination thereof. The device defines a device outlet. The pressure relief valve has a valve inlet fluidly connected to the interior region and a valve outlet fluidly connected to the device. The pressure relief valve is configured to transfer a gas from the interior region to the device when a pressure in the interior region exceeds a predetermined pressure. The spreader component is configured to be in fluid communication with the gas and direct the gas to the device outlet.

Abstract: Presented are battery assemblies with integrated fuel tanks, methods for making/using such battery assemblies, and fuel cell electric vehicles having rechargeable traction battery packs with integrated fiber-composite hydrogen fuel tanks. A rechargeable energy storage system (RESS) assembly includes a battery pack housing with an internal battery module compartment located between two tank mounting cavities. Each mounting cavity is recessed into a respective lateral side of the battery pack housing. Multiple rechargeable battery modules are electrically interconnected with one another and mounted inside the battery module compartment. Each battery module contains multiple battery cells, such as a stack of series-connected lithium-ion pouch cells. A fuel tank is mounted in each of the tank mounting cavities on the lateral sides of the battery pack housing.

Abstract: An electrochemical assembly includes a case defining an interior region, an electrochemical cell, a device, and a pressure relief valve. The electrochemical cell is disposed within the interior region. The device includes a spreader component. The spreader component includes a polymer matrix and an additive embedded in the polymer matrix. The additive includes an endothermic phase change material, a flame retardant material, an intumescent material, or any combination thereof. The device defines a device outlet. The pressure relief valve has a valve inlet fluidly connected to the interior region and a valve outlet fluidly connected to the device. The pressure relief valve is configured to transfer a gas from the interior region to the device when a pressure in the interior region exceeds a predetermined pressure. The spreader component is configured to be in fluid communication with the gas and direct the gas to the device outlet.

Abstract: A battery pack assembly includes a battery cell and a plurality of walls that surround the battery cell. The battery pack assembly also includes a heat exchanger coupled to the battery cell. The heat exchanger is configured to cool the battery cell. The heat exchanger includes a first frame and at least one channel supported via the first frame. The channel is configured to guide a liquid fluid through the channel to cool the battery cell. In certain configurations, the battery pack assembly includes a tray and a plurality of first battery cells electrically connected to each other to present a first cell stack. In certain configurations, the battery pack assembly includes a plurality of first walls that surround the first cell stack to define a first battery module coupled to the tray. The heat exchanger may be coupled to the tray and coupled to the first cell stack.

Abstract: A product may include a battery cell, and a housing may contain the battery cell. A cooling assembly may include an impeller that may circulate air in the housing. A turbine may be connected with the impeller so that the turbine and impeller may rotate together.

Abstract: A product may include a battery pack, and a housing may receive the battery pack. The housing may comprise a plastic containing an additive that is electrically insulating and that has a greater thermal conductivity than the plastic.

Abstract: A cooling system for a battery is provided which includes a first tube, a second tube and a middle section which may be formed from an electrically insulating yet thermally conductive material. The first tube and the second tube may each be adapted to transfer coolant from a first end to a second end. The middle section integral may be the first tube on the first side of the middle section and integral to the second tube on the second side of the middle section. The first tube, the second tube and the middle section may be operatively configured to draw thermal energy away from at least one bus bar and corresponding cell tabs for a battery.