Abstract: A modular battery system includes a battery pack with multiple battery modules electrically interconnected via a plurality of electrical cables. A plurality of switches selectively connects the multiple battery modules. A direct current (DC) charge connector is configured to electrically connect the battery pack to an off-board DC fast-charging station, via the plurality of electrical cables. The pack circuit is adapted to switch between a first configuration and a second configuration based on a respective position of the plurality of switches. A controller is configured to select the respective position of each of the plurality of switches to transition the pack circuit between the first configuration and the second configuration, in response to input signals indicative of a requested operating mode of the battery pack. The first configuration provides three parallel electrical pathways, and the second configuration provides two parallel electrical pathways.

Abstract: Presented are thermal management systems with passive quenching sacks for cooling battery assemblies, methods for making/using such systems, and vehicles equipped with such systems. A passive thermal management (PTM) system is presented for cooling a battery assembly, such as a traction battery pack with a battery case containing stacked battery cells. The PTM system includes a fluid container that mounts inside the battery assembly, interposed between the battery case and battery cells. The fluid container stows therein a dielectric coolant fluid and has multiple fluid ports that fluidly connect to the battery cells to dispense thereto the coolant fluid. Thermomechanical plugs, such as wax, film, or smart-material barriers, seal the fluid container ports and passively open (e.g., melt, bend, disintegrate, expand, etc.) at a predefined temperature to thereby unseal the fluid ports such that the coolant fluid is fed from the fluid container into the battery cells.

Abstract: A prismatic battery cell assembly has a prismatic container that includes a body portion composed of opposed first and second side portions, opposed first and second end portions, a bottom portion, and a top portion. An electrode stack is composed as anodes interleaved with cathodes. Each of the anodes includes a first current collector having an uncoated anode current collector portion that extends in a first direction away from the electrode stack, and each of the cathodes includes a second current collector having an uncoated cathode current collector portion that extends in a second direction away from the electrode stack. A first terminal is joined to the uncoated anode current collector portions of the first current collectors of the anodes, and a terminal is joined to the uncoated cathode current collector portions of the second current collectors of the cathodes.

Abstract: A separator mechanism for battery modules and methods of removing battery modules. The mechanism includes a battery pack having a first battery module and an adhesive configured to bond the first battery module to at least one other structure. A cut-out wire is configured to separate the adhesive between the first battery module and the other structure. The other structure may be a second battery module of the battery pack or a cold plate, such that the adhesive bonds the first battery module to second battery module or cold plate. The mechanism may include an attachment mechanism for attaching the cut-out wire to an automatic pulling system. The cut-out wire may be installed concurrently with the first battery module or after the first battery module is installed. One or more handles may be attached to one or more ends of the cut-out wire.

Abstract: A thermal management system for a rechargeable battery pack assembly includes a conduit having an upstream end and a downstream end, the downstream end operatively connectable to an enclosure of the rechargeable battery pack assembly at a port of the rechargeable battery pack assembly. A sealing mechanism is configured to transition from a first state in which the sealing mechanism blocks flow of an applied stream of water through the conduit from the upstream end through the port, to a second state in which the sealing mechanism permits flow from the upstream end to the port and through the port into the interior cavity to cool the interior cavity.

Abstract: A battery module with integrated pressure measurement. The battery module may include a plurality of battery cells configured for storing and supplying electrical power, a housing module including a base configured for supporting the battery cells and a plurality of walls configured for providing a restraining pressure on the battery cells, an assembly including a central cover covering the battery cells, a strain gauge circuit configured for sensing a deformation of the central cover resulting from the central cover expanding and contracting with the battery cells, and a cell monitoring unit (CMU) configured for generating a pressure measurement based on the deformation.

Abstract: An apparatus including a battery cell includes an electrode stack. The electrode stack includes an anode electrode, a cathode electrode, and a separator disposed between the anode electrode and the cathode electrode. The apparatus further includes an enclosure configured for encasing and mechanically protecting the electrode stack. The apparatus further includes an electrolyte. The apparatus further includes a thermally conductive and electrically insulated inert fill material located between the electrode stack and the enclosure configured for providing a thermally conductive connection between the electrode stack and the enclosure.

Abstract: An apparatus including a battery cell includes an electrode stack. The electrode stack includes an anode electrode, a cathode electrode, and a separator disposed between the anode electrode and the cathode electrode. The apparatus further includes an enclosure configured for encasing and mechanically protecting the electrode stack. The apparatus further includes an electrolyte. The apparatus further includes a thermally conductive and electrically insulated inert fill material located between the electrode stack and the enclosure configured for providing a thermally conductive connection between the electrode stack and the enclosure.

Abstract: A battery assembly includes a first plurality of battery cells, a second plurality of battery cells, and an intermediate layer arranged in a stack. Each of the first plurality of battery cells includes a first cathode, a first cathode current collector, a first anode, a first anode current collector, and a first solid state separator, and each of the second plurality of battery cells includes a second cathode, a second cathode current collector, a second anode, a second anode current collector, and a second solid state separator. The first cathode current collectors are electrically connected in parallel to a first terminal, and the second anode current collectors are electrically connected in parallel to a second terminal. The first anode current collectors of the first plurality of battery cells are electrically connected and are electrically connected to the second cathode current collectors of the second plurality of battery cells.

Abstract: Presented are thermal management systems with passive quenching sacks for cooling battery assemblies, methods for making/using such systems, and vehicles equipped with such systems. A passive thermal management (PTM) system is presented for cooling a battery assembly, such as a traction battery pack with a battery case containing stacked battery cells. The PTM system includes a fluid container that mounts inside the battery assembly, interposed between the battery case and battery cells. The fluid container stows therein a dielectric coolant fluid and has multiple fluid ports that fluidly connect to the battery cells to dispense thereto the coolant fluid. Thermomechanical plugs, such as wax, film, or smart-material barriers, seal the fluid container ports and passively open (e.g., melt, bend, disintegrate, expand, etc.) at a predefined temperature to thereby unseal the fluid ports such that the coolant fluid is fed from the fluid container into the battery cells.

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 finger-proof electrical terminals for battery assemblies, methods for making/using such electrical terminals, and vehicles with battery modules having finger-proof electrical terminals for bolted busbar connections. A battery assembly includes one or more electrochemical battery cells and one or more electrical terminals each electrically connected to the battery cell(s) and having a contact face to electrically connect the battery assembly to an electrical connector. A threaded nut attaches each electrical terminal to one of the electrical connectors. An electrically insulating nut cap is attached to each threaded nut. A battery housing, which stores therein the battery cell(s), includes an electrically insulating housing wall with one or more terminal jackets each mounting therein one of the electrical terminals.

Abstract: Presented are finger-proof electrical terminals for battery assemblies, methods for making/using such electrical terminals, and vehicles with battery modules having finger-proof electrical terminals for bolted busbar connections. A battery assembly includes one or more electrochemical battery cells and one or more electrical terminals each electrically connected to the battery cell(s) and having a contact face to electrically connect the battery assembly to an electrical connector. A threaded nut attaches each electrical terminal to one of the electrical connectors. An electrically insulating nut cap is attached to each threaded nut. A battery housing, which stores therein the battery cell(s), includes an electrically insulating housing wall with one or more terminal jackets each mounting therein one of the electrical terminals.

Abstract: A modular battery pack and method of making a battery pack. Prismatic can battery cells are interspersed with cooling frames along a stacking axis within a housing such that numerous a cell-frame assemblies, each with a cooling path, are formed. Resiliently-biased sealing members on the frames are arranged such that they remain out of the way of a footprint defined by the joined cells and frames to promote ease of high-speed cell-to-frame assembly. Upon formation of the cell-frame assembly and subsequent placement into the housing with inner walls that press against the protruding ends of the sealing member, the sealing member is forced by the housing to come into contact engagement with a corresponding surface of the edge of the battery cell. The generally linear, planar contact surface formed by the contact engagement promotes the formation of a sealing surface that makes it harder for introduced cooling air to escape.

Abstract: An electric joint formed between a high current source and a high current load, and a method of making electrical connection between them. In one form, the source is made up of one or more cells in a battery pack and the load is an electric motor. An electrical connection assembly includes a first conductor, a fastener and a second conductor joined together such that electrical continuity between the conductors is not established until the fastener imparts a substantially normal force to both of them in such a way that they become secured together to produce a deformable shape to adjacently-facing surfaces one or both conductors, thereby ensuring significant contact and a related low electrical resistance as a way to avoid imperfect or partial attachments at the joint.

Abstract: An electric joint formed between a high current source and a high current load, and a method of making electrical connection between them. In one form, the source is made up of one or more cells in a battery pack and the load is an electric motor. An electrical connection assembly includes a first conductor, a fastener and a second conductor joined together such that electrical continuity between the conductors is not established until the fastener imparts a substantially normal force to both of them in such a way that they become secured together to produce a deformable shape to adjacently-facing surfaces one or both conductors, thereby ensuring significant contact and a related low electrical resistance as a way to avoid imperfect or partial attachments at the joint.

Abstract: A modular battery pack and method of making a battery pack. Prismatic can battery cells are interspersed with cooling frames along a stacking axis within a housing such that numerous a cell-frame assemblies, each with a cooling path, are formed. Resiliently-biased sealing members on the frames are arranged such that they remain out of the way of a footprint defined by the joined cells and frames to promote ease of high-speed cell-to-frame assembly. Upon formation of the cell-frame assembly and subsequent placement into the housing with inner walls that press against the protruding ends of the sealing member, the sealing member is forced by the housing to come into contact engagement with a corresponding surface of the edge of the battery cell. The generally linear, planar contact surface formed by the contact engagement promotes the formation of a sealing surface that makes it harder for introduced cooling air to escape.

Abstract: System and methods for retaining a battery system included in a vehicle are presented. In certain embodiments, a system for enclosing a battery system may utilize a plurality of modular components. The modular components may include a plurality of first side components and a plurality of second side components coupled to the plurality of first side components. A first top component and a second top component may be coupled to the first side components. In certain embodiments, the second top component may be configured to prevent the first top component from being decoupled from the first side components.

Abstract: A modular battery pack and method of making a battery pack. The modular structure includes an open box with an interlocking features to allow for flexibility in assembly of numerous battery pack configurations. The design is such that numerous sub-module assemblies are formed that can be fastened, connected or otherwise secured to a tray, frame or other underlying primary support structure. Aligned stacks of individual battery cells can be placed within the volume defined within the box-like structure so that portions of the box-like structure move in response to a spring-like force imparted by the stack of battery cells. Adapter plates facilitate the modular construction by an interlocking connection between the box-like structure and the underlying support structure.

Abstract: An alarm system for a vehicle charge cord is provided. The alarm system has an armed state and a disarmed state. The alarm system includes a battery, a charge cord sensor, a battery state estimator (“BSE”) module, and an interface module. The battery has state of charge (“SOC”), and is rechargeable to a predetermined level of charge. The charge cord sensor is configured to detect if the vehicle charge cord is connected to or disconnected from a vehicle. The BSE module is configured to monitor the SOC of the rechargeable battery and determine if the battery is charged to the predetermined level of charge. The interface module is in communication with the charge cord sensor and the BSE module. The interface module is configured to switch the alarm system from the armed state to the disarmed state.